U.S. patent application number 15/316598 was filed with the patent office on 2017-05-18 for semiconductor device and method of manufacturing the same.
The applicant listed for this patent is SONY CORPORATION. Invention is credited to MAKOTO MURAI, YUJI TAKAOKA.
Application Number | 20170141064 15/316598 |
Document ID | / |
Family ID | 54937934 |
Filed Date | 2017-05-18 |
United States Patent
Application |
20170141064 |
Kind Code |
A1 |
MURAI; MAKOTO ; et
al. |
May 18, 2017 |
SEMICONDUCTOR DEVICE AND METHOD OF MANUFACTURING THE SAME
Abstract
A semiconductor chip includes a chip body and a plurality of
solder-including electrodes provided on an element-formation
surface of the chip body. A packaging substrate includes a
substrate body, a plurality of wirings, and a solder resist layer,
in which the plurality of wirings and the solder resist layer are
provided on a front surface of the substrate body. The solder
resist layer is provided as a continuous layer on the front surface
of the substrate body and the plurality of wirings, and has an
aperture on each of the plurality of wirings. The plurality of
solder-including electrodes include at least one gap control
electrode. The at least one gap control electrode includes a
columnar metal layer and a solder layer in order named from side on
which the chip body is disposed, and includes an overlap region
where the columnar metal layer and the solder resist layer overlap
each other, along part or all of an aperture end of the
aperture.
Inventors: |
MURAI; MAKOTO; (TOKYO,
JP) ; TAKAOKA; YUJI; (KANAGAWA, JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
SONY CORPORATION |
TOKYO |
|
JP |
|
|
Family ID: |
54937934 |
Appl. No.: |
15/316598 |
Filed: |
June 5, 2015 |
PCT Filed: |
June 5, 2015 |
PCT NO: |
PCT/JP2015/066349 |
371 Date: |
December 6, 2016 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
H01L 2225/06517
20130101; H01L 23/49838 20130101; H01L 2224/05647 20130101; Y02P
70/50 20151101; H01L 2924/15311 20130101; Y02P 70/613 20151101;
H01L 24/92 20130101; H01L 2224/81455 20130101; H01L 2224/81801
20130101; H01L 2224/13155 20130101; H01L 2224/16113 20130101; H01L
2224/83201 20130101; H01L 2225/06562 20130101; H01L 2224/16237
20130101; H01L 21/563 20130101; H01L 2224/81201 20130101; H01L
24/16 20130101; H01L 2224/16225 20130101; H01L 2224/48091 20130101;
H01L 2224/16013 20130101; H05K 3/3436 20130101; H01L 2224/2929
20130101; H01L 24/13 20130101; H01L 2224/05166 20130101; H01L
2224/1147 20130101; H01L 2224/16057 20130101; H01L 2224/32225
20130101; H01L 2224/81203 20130101; H01L 2924/01028 20130101; H01L
2224/13147 20130101; H01L 2224/48106 20130101; H01L 24/11 20130101;
H01L 25/105 20130101; H01L 2225/0651 20130101; H05K 2201/099
20130101; H05K 2201/0989 20130101; H01L 2225/06586 20130101; H01L
2924/01079 20130101; H01L 2224/05624 20130101; H01L 2924/014
20130101; H01L 2224/83862 20130101; H01L 2924/181 20130101; H01L
25/0657 20130101; H01L 2224/83192 20130101; H01L 2924/15331
20130101; H01L 2224/45099 20130101; H01L 2224/81464 20130101; H01L
2224/81815 20130101; H01L 2224/13111 20130101; H01L 2224/13082
20130101; H01L 2224/29386 20130101; H01L 2225/06572 20130101; H01L
23/12 20130101; H01L 2224/05124 20130101; H01L 2224/81385 20130101;
H01L 2924/01046 20130101; H01L 24/73 20130101; H01L 24/83 20130101;
H01L 2224/8112 20130101; H01L 2224/16227 20130101; H01L 2224/83856
20130101; H01L 2924/15747 20130101; H01L 2224/48227 20130101; H01L
2224/92125 20130101; H01L 2924/1436 20130101; H05K 2201/10674
20130101; H01L 2224/16055 20130101; H01L 2224/13083 20130101; H01L
2224/73204 20130101; H01L 2224/13139 20130101; H01L 2224/13109
20130101; H01L 2224/81191 20130101; H01L 2225/0652 20130101; H01L
23/49866 20130101; H01L 24/81 20130101; H01L 2224/81444 20130101;
H01L 2924/00014 20130101; H01L 2924/1434 20130101; H01L 2924/181
20130101; H01L 2924/00012 20130101; H01L 2224/48091 20130101; H01L
2924/00014 20130101; H01L 2224/73204 20130101; H01L 2224/16225
20130101; H01L 2224/32225 20130101; H01L 2924/00012 20130101; H01L
2924/15311 20130101; H01L 2224/73204 20130101; H01L 2224/16225
20130101; H01L 2224/32225 20130101; H01L 2924/00012 20130101; H01L
2924/00014 20130101; H01L 2224/45099 20130101; H01L 2224/73204
20130101; H01L 2224/32225 20130101; H01L 2224/16225 20130101; H01L
2924/00012 20130101; H01L 2224/13147 20130101; H01L 2924/00014
20130101; H01L 2224/13155 20130101; H01L 2924/00014 20130101; H01L
2224/13111 20130101; H01L 2924/01047 20130101; H01L 2224/13111
20130101; H01L 2924/01029 20130101; H01L 2224/13109 20130101; H01L
2924/01047 20130101; H01L 2924/1436 20130101; H01L 2924/00012
20130101; H01L 2924/1434 20130101; H01L 2924/00012 20130101; H01L
2224/45099 20130101; H01L 2924/00014 20130101; H01L 2224/13111
20130101; H01L 2924/014 20130101; H01L 2924/01047 20130101; H01L
2924/00014 20130101; H01L 2224/13139 20130101; H01L 2924/014
20130101; H01L 2924/01049 20130101; H01L 2924/00014 20130101; H01L
2224/05166 20130101; H01L 2924/013 20130101; H01L 2924/01074
20130101; H01L 2924/00014 20130101; H01L 2224/13139 20130101; H01L
2924/014 20130101; H01L 2924/0105 20130101; H01L 2924/00014
20130101; H01L 2224/05624 20130101; H01L 2924/00014 20130101; H01L
2224/81444 20130101; H01L 2924/013 20130101; H01L 2924/01028
20130101; H01L 2924/01046 20130101; H01L 2924/00014 20130101; H01L
2224/81455 20130101; H01L 2924/013 20130101; H01L 2924/01046
20130101; H01L 2924/01079 20130101; H01L 2924/00014 20130101; H01L
2224/13109 20130101; H01L 2924/014 20130101; H01L 2924/01047
20130101; H01L 2924/00014 20130101; H01L 2224/2929 20130101; H01L
2924/00014 20130101; H01L 2224/05124 20130101; H01L 2924/00014
20130101; H01L 2224/05647 20130101; H01L 2924/00014 20130101; H01L
2224/29386 20130101; H01L 2924/05442 20130101; H01L 2924/00014
20130101; H01L 2224/81464 20130101; H01L 2924/013 20130101; H01L
2924/01028 20130101; H01L 2924/01079 20130101; H01L 2924/00014
20130101 |
International
Class: |
H01L 23/00 20060101
H01L023/00; H01L 21/56 20060101 H01L021/56; H01L 23/498 20060101
H01L023/498 |
Foreign Application Data
Date |
Code |
Application Number |
Jun 27, 2014 |
JP |
2014-132333 |
Claims
1. A semiconductor device, comprising: a semiconductor chip; and a
packaging substrate on which the semiconductor chip is mounted,
wherein the semiconductor chip includes a chip body and a plurality
of solder-including electrodes provided on an element-formation
surface of the chip body, the packaging substrate includes a
substrate body, a plurality of wirings, and a solder resist layer,
the plurality of wirings and the solder resist layer being provided
on a front surface of the substrate body, the solder resist layer
is provided as a continuous layer on the front surface of the
substrate body and the plurality of wirings, and has an aperture on
each of the plurality of wirings, the plurality of solder-including
electrodes include at least one gap control electrode, and the at
least one gap control electrode includes a columnar metal layer and
a solder layer in order named from side on which the chip body is
disposed, and includes an overlap region where the columnar metal
layer and the solder resist layer overlap each other, along part or
all of an aperture end of the aperture.
2. The semiconductor device according to claim 1, wherein the at
least one gap control electrode includes a plurality of gap control
electrodes, and at least one of the plurality of gap control
electrodes is disposed at each side of the semiconductor chip.
3. The semiconductor device according to claim 1, wherein, in the
at least one gap control electrode, a diameter of the columnar
metal layer is larger than a width of the aperture, along part or
all of the aperture end of the aperture.
4. The semiconductor device according to claim 1, wherein, in the
at least one gap control electrode, a center of the columnar metal
layer is out of alignment with a center of the aperture.
5. The semiconductor device according to claim 1, wherein the
aperture has a planar shape elongated in a lengthwise direction of
the wiring inside the aperture, with a length of the aperture
adjusted in accordance with a thermal expansion coefficient of the
packaging substrate.
6. The semiconductor device according to claim 1, wherein the
columnar metal layer is made of a metal having a higher melting
point than a melting point of solder that constitutes the solder
layer.
7. The semiconductor device according to claim 6, wherein a height
of the columnar metal layer is larger than a height of the solder
layer.
8. The semiconductor device according to claim 6, wherein a volume
of the solder layer is larger than a volume of the aperture.
9. The semiconductor device according to claim 5, wherein the
length of the aperture satisfies Expression 1.
L>(a-3.5)*D*(T-25)*10-6+d Expression 1 (in Expression 1, L
denotes the length (mm) of the aperture, a denotes an equivalent
thermal expansion coefficient (ppm/.degree. C.) of the packaging
substrate, D denotes a distance (mm) from a center of the packaging
substrate to a center of the aperture, T denotes a melting point
(.degree. C.) of the solder, and d denotes a diameter of each of
the plurality of solder-including electrodes.)
10. The semiconductor device according to claim 1, wherein each of
the plurality of wirings includes: a metal wiring layer made of
copper (Cu) as a principal component; and a surface coating that
covers a region exposed in the aperture, out of a surface of the
metal wiring layer.
11. The semiconductor device according to claim 10, wherein the
surface coating includes an Ni--Au plating layer or a Ni--Pd--Au
plating layer.
12. The semiconductor device according to claim 1, wherein the
columnar metal layer is made of copper (Cu), or includes a stacked
film of copper (Cu) and nickel (Ni), and the solder layer is made
of tin (Sn) or Sn--Ag.
13. The semiconductor device according to claim 1, wherein the
columnar metal layer is made of copper (Cu), or includes a stacked
film of copper (Cu) and nickel (Ni), and the solder layer is made
of indium (In) or In--Ag.
14. A method of manufacturing a semiconductor device, the method
comprising: aligning a semiconductor chip with a packaging
substrate, the semiconductor chip including a chip body and a
plurality of solder-including electrodes provided on an
element-formation surface of the chip body, and the packaging
substrate including a substrate body, a plurality of wirings, and a
solder resist layer, the plurality of wirings and the solder resist
layer being provided on a front surface of the substrate body;
temporarily bonding the semiconductor chip to the packaging
substrate; connecting the plurality of solder-including electrodes
to the plurality of wirings, by reflow heating; and injecting an
underfill resin between the semiconductor chip and the packaging
substrate, and curing the underfill resin, wherein the solder
resist layer is provided as a continuous layer on the front surface
of the substrate body and the plurality of wirings, and has an
aperture on each of the plurality of wirings, the plurality of
solder-including electrodes include at least one gap control
electrode, the at least one gap control electrode includes a
columnar metal layer and a solder layer in order named from side on
which the chip body is disposed, and the temporarily bonding of the
semiconductor chip to the packaging substrate includes heating the
semiconductor chip and pressure-bonding the semiconductor chip to
the packaging substrate, and detecting a load by allowing the
columnar metal layer of the at least one gap control electrode and
the solder resist layer to be in contact with each other.
15. A method of manufacturing a semiconductor device, the method
comprising: aligning a semiconductor chip with a packaging
substrate after heating the semiconductor chip at a temperature
equal to or higher than a melting point of solder, the
semiconductor chip including a chip body and a plurality of
solder-including electrodes provided on an element-formation
surface of the chip body, and the packaging substrate including a
substrate body, a plurality of wirings, and a solder resist layer,
the plurality of wirings and the solder resist layer being provided
on a front surface of the substrate body; connecting the plurality
of solder-including electrodes to the plurality of wirings; and
injecting an underfill resin between the semiconductor chip and the
packaging substrate, and curing the underfill resin, wherein the
solder resist layer is provided as a continuous layer on the front
surface of the substrate body and the plurality of wirings, and has
an aperture on each of the plurality of wirings, the plurality of
solder-including electrodes include at least one gap control
electrode, the at least one gap control electrode includes a
columnar metal layer and a solder layer in order named from side on
which the chip body is disposed, and the connecting of the
plurality of solder-including electrodes to the plurality of
wirings includes pressure-bonding the semiconductor chip to the
packaging substrate, detecting a load by allowing the columnar
metal layer of the at least one gap control electrode and the
solder resist layer to be in contact with each other, and adjusting
a gap between the semiconductor chip and the packaging
substrate.
16. A method of manufacturing a semiconductor device, the method
comprising: aligning a semiconductor chip with a packaging
substrate, the semiconductor chip including a chip body and a
plurality of solder-including electrodes provided on an
element-formation surface of the chip body, and the packaging
substrate including a substrate body, a plurality of wirings, and a
solder resist layer, the plurality of wirings and the solder resist
layer being provided on a front surface of the substrate body;
connecting the plurality of solder-including electrodes to the
plurality of wirings; and injecting an underfill resin between the
semiconductor chip and the packaging substrate, and curing the
underfill resin, wherein the solder resist layer is provided as a
continuous layer on the front surface of the substrate body and the
plurality of wirings, and has an aperture on each of the plurality
of wirings, the plurality of solder-including electrodes include at
least one gap control electrode, the at least one gap control
electrode includes a columnar metal layer and a solder layer in
order named from side on which the chip body is disposed, and the
connecting of the plurality of solder-including electrodes to the
plurality of wirings includes pressure-bonding the semiconductor
chip to the packaging substrate, detecting a load by allowing the
columnar metal layer of the at least one gap control electrode and
the solder resist layer to be in contact with each other, and
heating the semiconductor chip at a temperature equal to or higher
than a melting point of the solder and pressure-bonding the
semiconductor chip to the packaging substrate, to connect the
plurality of solder-including electrodes to the plurality of
wirings.
17. A method of manufacturing a semiconductor device, the method
comprising: supplying an underfill resin on a packaging substrate,
the packaging substrate including a substrate body, a plurality of
wirings, and a solder layer, the plurality of wirings and the
solder resist layer being provided on a front surface of the
substrate body; aligning a semiconductor chip with the packaging
substrate, the semiconductor chip including a chip body and a
plurality of solder-including electrodes provided on an
element-formation surface of the chip body; connecting the
plurality of solder-including electrodes to the plurality of
wirings, and temporarily curing the underfill resin; and
permanently curing the underfill resin, wherein the solder resist
layer is provided as a continuous layer on the front surface of the
substrate body and the plurality of wirings, and has an aperture on
each of the plurality of wirings, the plurality of solder-including
electrodes include at least one gap control electrode, the at least
one gap control electrode includes a columnar metal layer and a
solder layer in order named from side on which the chip body is
disposed, and the connecting of the plurality of solder-including
electrodes to the plurality of wirings includes pressure-bonding
the semiconductor chip to the packaging substrate, detecting a load
by allowing the columnar metal layer of the at least one gap
control electrode and the solder resist layer to be in contact with
each other, and heating the semiconductor chip at a temperature
equal to or higher than a melting point of the solder and
pressure-bonding the semiconductor chip to the packaging substrate,
to connect the plurality of solder-including electrodes to the
plurality of wirings.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a U.S. National Phase of International
Patent Application No. PCT/JP2015/066349 filed on Jun. 5, 2015,
which claims priority benefit of Japanese Patent Application No. JP
2014-132333 filed in the Japan Patent Office on Jun. 27, 2014. Both
of the above-referenced applications is hereby incorporated herein
by reference in its entirety.
TECHNICAL FIELD
[0002] The disclosure relates to a semiconductor device that
utilizes a flip chip technique, and a method of manufacturing the
semiconductor device.
BACKGROUND ART
[0003] In recent years, apparatuses having picture output
functions, e.g., smartphones, tablet computers, television
receivers, and game machines, have had remarkable improvement in
display resolution. For adaptation thereto, there has been
expansion of a memory band desired for an image processor LSI
(Large Scale Integrated Circuit) installed in such apparatuses.
Known techniques to achieve a wide memory band may include Chip on
Chip (CoC), as disclosed in Patent Literature 1. However, the CoC
technique may tend to incur higher costs, because of use of DRAM
(Dynamic Random Access Memory) having a special interface, or use
of techniques such as fine connection using microbumps. A general
approach may be, therefore, to use a plurality of DRAMs having a
standard DDR (Double Data Rate) interface and to ensure the memory
band by increasing the number of connection channels between the
image processor LSI and the DRAMs. A 64-bit interface is in actual
use in apparatuses such as smartphones, and the use of such an
interface is expected to be spreading in the future.
[0004] Moreover, miniaturization of semiconductor devices has
allowed for integration of a greater number of transistors in a
chip. This has made it possible to integrate even more functions in
one chip. For example, an application processor currently used in
the smartphone or the tablet computer, and the LSI incorporated in
a digital television receiver mainly use what unitizes CPU (Central
Processing Unit), GPU (Graphics Processing Unit), and various
interfaces as one chip.
[0005] Such advances in multi-channeling of a memory interface and
in functional integration in one chip have caused a tendency of an
increase in the number of terminals that connect the LSI to
outside. In related arts, a packaging method has been generally
adopted in which a semiconductor chip is connected to a packaging
substrate by wire bonding. In recent years, however, in order to
adapt to the increase in the connection terminals, adoption of a
so-called flip chip technique has been increasing. The flip chip
technique involves connecting the semiconductor chip to the
packaging substrate with use of solder bumps. In particular, a
technique generally used in the flip chip technique is called C4
(Controlled Collapse Chip Connection), as disclosed in, for
example, Patent Literature 2.
[0006] In the C4 technique, on side of the packaging substrate, a
solder resist may be provided in advance with apertures. The
apertures each may have a substantially same size as a size of a
solder bump to be used for connection. A paste solder material may
be printed in the apertures. Then, a chip provided in advance with
solder bumps may be mounted on the printed solder material, with
use of flux. By a batch reflow method, the solder may melt to form
connection. An underfill resin may be filled for sealing, between
the chip and the packaging substrate. With this technique used,
miniaturization of an inter-terminal pitch may become difficult,
for the following reasons. First, in order to ensure a gap between
the chip and the packaging substrate to fill the underfill resin,
it is desirable to increase a diameter of the solder bump formed on
side of the chip. Second, the solder paste may be formed by a
printing method, causing difficulty in formation of fine patterns.
Accordingly, the pitch between the connection terminals may become
about 150 .mu.m to 180 .mu.m both inclusive. This leads to
expectation of difficulty in adaptation to an increase in the
number of signals in the future, or to chip shrinkage due to device
miniaturization.
[0007] In view of the current situation as described above, Patent
Literature 3 discloses a technique that involves performing flip
chip directly on wirings, for purpose of a further increase in
signal terminal density and reduction in substrate costs. In the
existing C4 technique, a land having a larger size than the bump
diameter may be formed on the packaging substrate. In contrast, in
this technique, a bump may be pressed onto a wiring having a
smaller width than a bump diameter, to join the bump and the wiring
together, with the wiring forcing itself into the bump. Thus, this
technique has made improvement in an effort to attain high bonding
strength even in a case with use of bumps having small diameters.
In addition, a bump structure may be generally used in which solder
plating is performed on a metal pillar, or a so-called pillar. This
makes it possible to ensure the gap, between the chip and the
packaging substrate, desirable for injection of the underfill resin
even in the case with use of bumps having small diameters.
CITATION LIST
Patent Literature
[0008] Patent Literature 1: JP 2010-192886A [0009] Patent
Literature 2: Specification of U.S. Pat. No. 5,900,675 [0010]
Patent Literature 3: JP 2012-119648A
SUMMARY OF INVENTION
[0011] However, the use of such a bump structure having a solder
layer at a tip of a columnar metal layer may cause difficulty in
controlling a gap between a semiconductor chip and a packaging
substrate. Accordingly, if a gap between the columnar metal layer
and a wiring becomes excessively narrow, solder interposed between
the columnar metal layer and the wiring may be expelled, causing a
short circuit with an adjacent wiring.
[0012] It is therefore desirable to provide a semiconductor device
and a method of manufacturing the same that make it possible to
stably control a gap between a semiconductor chip and a packaging
substrate and to suppress a short circuit between adjacent
wirings.
[0013] A semiconductor device according to an embodiment of the
disclosure includes a semiconductor chip, and a packaging substrate
on which the semiconductor chip is mounted. The semiconductor chip
includes a chip body and a plurality of solder-including electrodes
provided on an element-formation surface of the chip body. The
packaging substrate includes a substrate body, a plurality of
wirings, and a solder resist layer, in which the plurality of
wirings and the solder resist layer are provided on a front surface
of the substrate body. The solder resist layer is provided as a
continuous layer on the front surface of the substrate body and the
plurality of wirings, and has an aperture on each of the plurality
of wirings. The plurality of solder-including electrodes include at
least one gap control electrode. The at least one gap control
electrode includes a columnar metal layer and a solder layer in
order named from side on which the chip body is disposed, and
includes an overlap region where the columnar metal layer and the
solder resist layer overlap each other, along part or all of an
aperture end of the aperture.
[0014] In the semiconductor device according to the embodiment of
the disclosure, the plurality of solder-including electrodes
include the at least one gap control electrode. The at least one
gap control electrode includes the overlap region where the
columnar metal layer and the solder resist layer overlap each
other, along part or all of the aperture end of the aperture. Thus,
a gap between the semiconductor chip and the packaging substrate is
defined as a value equal to or larger than a height of the columnar
metal layer. Accordingly, the gap between the semiconductor chip
and the packaging substrate is restrained from becoming excessively
small, and causing the solder interposed between the columnar metal
layer and the wiring to be expelled, for example. Hence, a short
circuit between the adjacent wirings is suppressed.
[0015] A first method of manufacturing a semiconductor device
according to an embodiment of the disclosure includes: aligning a
semiconductor chip with a packaging substrate, in which the
semiconductor chip includes a chip body and a plurality of
solder-including electrodes provided on an element-formation
surface of the chip body, and the packaging substrate includes a
substrate body, a plurality of wirings, and a solder resist layer,
in which the plurality of wirings and the solder resist layer are
provided on a front surface of the substrate body; temporarily
bonding the semiconductor chip to the packaging substrate;
connecting the plurality of solder-including electrodes to the
plurality of wirings, by reflow heating; and injecting an underfill
resin between the semiconductor chip and the packaging substrate,
and curing the underfill resin. The solder resist layer is provided
as a continuous layer on the front surface of the substrate body
and the plurality of wirings, and has an aperture on each of the
plurality of wirings. The plurality of solder-including electrodes
include at least one gap control electrode. The at least one gap
control electrode includes a columnar metal layer and a solder
layer in order named from side on which the chip body is disposed.
The temporarily bonding of the semiconductor chip to the packaging
substrate includes heating the semiconductor chip and
pressure-bonding the semiconductor chip to the packaging substrate,
and detecting a load by allowing the columnar metal layer of the at
least one gap control electrode and the solder resist layer to be
in contact with each other.
[0016] A second method of manufacturing a semiconductor device
according to an embodiment of the disclosure includes: aligning a
semiconductor chip with a packaging substrate after heating the
semiconductor chip at a temperature equal to or higher than a
melting point of solder, in which the semiconductor chip includes a
chip body and a plurality of solder-including electrodes provided
on an element-formation surface of the chip body, and the packaging
substrate includes a substrate body, a plurality of wirings, and a
solder resist layer, in which the plurality of wirings and the
solder resist layer are provided on a front surface of the
substrate body; connecting the plurality of solder-including
electrodes to the plurality of wirings; and injecting an underfill
resin between the semiconductor chip and the packaging substrate,
and curing the underfill resin. The solder resist layer is provided
as a continuous layer on the front surface of the substrate body
and the plurality of wirings, and has an aperture on each of the
plurality of wirings. The plurality of solder-including electrodes
include at least one gap control electrode. The at least one gap
control electrode includes a columnar metal layer and a solder
layer in order named from side on which the chip body is disposed.
The connecting of the plurality of solder-including electrodes to
the plurality of wirings includes pressure-bonding the
semiconductor chip to the packaging substrate, detecting a load by
allowing the columnar metal layer of the at least one gap control
electrode and the solder resist layer to be in contact with each
other, and adjusting a gap between the semiconductor chip and the
packaging substrate.
[0017] A third method of manufacturing a semiconductor device
according to an embodiment of the disclosure includes: aligning a
semiconductor chip with a packaging substrate, in which the
semiconductor chip includes a chip body and a plurality of
solder-including electrodes provided on an element-formation
surface of the chip body, and the packaging substrate includes a
substrate body, a plurality of wirings, and a solder resist layer,
in which the plurality of wirings and the solder resist layer are
provided on a front surface of the substrate body; connecting the
plurality of solder-including electrodes to the plurality of
wirings; and injecting an underfill resin between the semiconductor
chip and the packaging substrate, and curing the underfill resin.
The solder resist layer is provided as a continuous layer on the
front surface of the substrate body and the plurality of wirings,
and has an aperture on each of the plurality of wirings. The
plurality of solder-including electrodes include at least one gap
control electrode. The at least one gap control electrode includes
a columnar metal layer and a solder layer in order named from side
on which the chip body is disposed. The connecting of the plurality
of solder-including electrodes to the plurality of wirings includes
pressure-bonding the semiconductor chip to the packaging substrate,
detecting a load by allowing the columnar metal layer of the at
least one gap control electrode and the solder resist layer to be
in contact with each other, and heating the semiconductor chip at a
temperature equal to or higher than a melting point of the solder
and pressure-bonding the semiconductor chip to the packaging
substrate, to connect the plurality of solder-including electrodes
to the plurality of wirings.
[0018] A fourth method of manufacturing a semiconductor device
according to an embodiment of the disclosure includes: supplying an
underfill resin on a packaging substrate, in which the packaging
substrate includes a substrate body, a plurality of wirings, and a
solder layer, in which the plurality of wirings and the solder
resist layer are provided on a front surface of the substrate body;
aligning a semiconductor chip with the packaging substrate, in
which the semiconductor chip includes a chip body and a plurality
of solder-including electrodes provided on an element-formation
surface of the chip body; connecting the plurality of
solder-including electrodes to the plurality of wirings, and
temporarily curing the underfill resin; and permanently curing the
underfill resin. The solder resist layer is provided as a
continuous layer on the front surface of the substrate body and the
plurality of wirings, and has an aperture on each of the plurality
of wirings. The plurality of solder-including electrodes include at
least one gap control electrode. The at least one gap control
electrode includes a columnar metal layer and a solder layer in
order named from side on which the chip body is disposed. The
connecting of the plurality of solder-including electrodes to the
plurality of wirings includes pressure-bonding the semiconductor
chip to the packaging substrate, detecting a load by allowing the
columnar metal layer of the at least one gap control electrode and
the solder resist layer to be in contact with each other, and
heating the semiconductor chip at a temperature equal to or higher
than a melting point of the solder and pressure-bonding the
semiconductor chip to the packaging substrate, to connect the
plurality of solder-including electrodes to the plurality of
wirings.
[0019] According to the semiconductor device of the embodiment of
the disclosure, the plurality of solder-including electrodes
include the at least one gap control electrode. The at least one
gap control electrode includes the overlap region where the
columnar metal layer and the solder resist layer overlap each
other, along part or all of the aperture end of the aperture.
Hence, it is possible to stably control the gap between the
semiconductor chip and the package substrate, and thereby to
suppress the short circuit between the adjacent wirings.
[0020] According to the first to fourth methods of manufacturing
the semiconductor devices of the embodiments of the disclosure, the
plurality of solder-including electrodes are formed to include the
at least one gap control electrode. In heating the semiconductor
chip and pressure-bonding the semiconductor chip to the packaging
substrate, or in pressure-boding the semiconductor chip to the
packaging substrate, the load is detected by allowing the columnar
metal layer of the at least one gap control electrode and the
solder resist layer to be in contact with each other. Hence, it is
possible to easily manufacture the semiconductor device of the
embodiment of the disclosure.
[0021] It is to be noted that some effects described here are not
necessarily limitative, and any of other effects described herein
may be achieved.
BRIEF DESCRIPTION OF DRAWINGS
[0022] FIG. 1 is a schematic top view of an overall configuration
of a semiconductor device according to a first embodiment of the
disclosure.
[0023] FIG. 2 is a schematic cross-sectional view of the overall
configuration of the semiconductor device illustrated in FIG.
1.
[0024] FIG. 3 is an enlarged top view of part of the semiconductor
device illustrated in FIG. 1.
[0025] FIG. 4 is a cross-sectional view taken along a line IV-IV of
FIG. 3.
[0026] FIG. 5 is an enlarged cross-sectional view of part of a
semiconductor device according to a modification example 1-1.
[0027] FIG. 6 is an enlarged top view of part of a semiconductor
device according to a second embodiment of the disclosure.
[0028] FIG. 7 is a cross-sectional view taken along a line VII-VII
of FIG. 6.
[0029] FIG. 8 is a cross-sectional view taken along a line
VIII-VIII of FIG. 6.
[0030] FIG. 9 is a cross-sectional view that illustrates an example
of positional deviation between an aperture and a solder-including
electrode.
[0031] FIG. 10 is an enlarged top view of part of a semiconductor
device according to a modification example 2-1.
[0032] FIG. 11 is a top view that illustrates a case with an
aperture having a rectangular planar shape.
[0033] FIG. 12 is an enlarged top view of part of a semiconductor
device according to a modification example 2-2.
[0034] FIG. 13 is an enlarged top view of part of a semiconductor
device according to a modification example 2-3.
[0035] FIG. 14 is a cross-sectional view taken along a line XIV-XIV
of FIG. 13.
[0036] FIG. 15 is an enlarged top view of part of a semiconductor
device according to a modification example 2-4.
[0037] FIG. 16 is an enlarged top view of part of a semiconductor
device according to a modification example 2-5.
[0038] FIG. 17 is an enlarged cross-sectional view of part of a
semiconductor device according to a third embodiment of the
disclosure.
[0039] FIG. 18 is a schematic top view of an overall configuration
of a semiconductor device according to a fourth embodiment of the
disclosure.
[0040] FIG. 19 is a schematic cross-sectional view of the overall
configuration of the semiconductor device illustrated in FIG.
18.
[0041] FIG. 20 is a schematic cross-sectional view of an overall
configuration of a semiconductor device according to a fifth
embodiment of the disclosure.
[0042] FIG. 21 is a schematic cross-sectional view of an overall
configuration of a semiconductor device according to a modification
example 5-1.
[0043] FIG. 22 is a schematic cross-sectional view of an overall
configuration of a semiconductor device according to a modification
example 5-2.
[0044] FIG. 23 is a cross-sectional view that illustrates a method
of manufacturing a semiconductor device according to a sixth
embodiment of the disclosure in the order of procedure, and is a
cross-sectional view that illustrates a method of manufacturing a
solder-including electrode illustrated in FIG. 7 in the order of
procedure.
[0045] FIG. 24 is a cross-sectional view of a process following
FIG. 23.
[0046] FIG. 25 is a cross-sectional view of a process following
FIG. 24.
[0047] FIG. 26 is a cross-sectional view of a process following
FIG. 25.
[0048] FIG. 27 is a cross-sectional view of a process following
FIG. 26.
[0049] FIG. 28 is a cross-sectional view of a process following
FIG. 27.
[0050] FIG. 29 is a cross-sectional view of a process following
FIG. 28.
[0051] FIG. 30 is a cross-sectional view of a process following
FIG. 29.
[0052] FIG. 31 is a cross-sectional view that illustrates a method
of manufacturing a semiconductor device according to a seventh
embodiment of the disclosure in the order of procedure, and is a
cross-sectional view that illustrates a method of connecting a
packaging substrate to a semiconductor chip illustrated in FIG. 7
in the order of procedure.
[0053] FIG. 32 is a cross-sectional view of a process following
FIG. 31.
[0054] FIG. 33 is a cross-sectional view of a process following
FIG. 32.
[0055] FIG. 34 is a cross-sectional view of a process following
FIG. 33.
[0056] FIG. 35 is a cross-sectional view that illustrates a method
of manufacturing a semiconductor device according to a tenth
embodiment of the disclosure in the order of procedure.
[0057] FIG. 36 is a cross-sectional view of a process following
FIG. 35.
[0058] FIG. 37 is a cross-sectional view of a process following
FIG. 36.
DESCRIPTION OF EMBODIMENTS
[0059] In the following, some embodiments of the disclosure are
described in detail with reference to the drawings. Note that
description is made in the following order.
[0060] 1. First Embodiment (a semiconductor device; an example in
which an aperture of a solder resist layer has a circular shape,
and a diameter of a columnar metal layer is larger than a width
(diameter) of the aperture)
[0061] 2. Modification Example 1-1 (an example in which a center of
the columnar metal layer is out of alignment with a center of the
aperture)
[0062] 3. Second Embodiment (a semiconductor device; an example in
which an aperture of a solder resist layer has a substantially
rectangular planar shape, with a length of the aperture adjusted in
accordance with a thermal expansion coefficient of a packaging
substrate)
[0063] 4. Modification Example 2-1 (an example in which the
aperture has a planar shape of an ellipse)
[0064] 5. Modification Example 2-2 (an example in which, inside the
aperture, a wiring includes a widened part)
[0065] 6. Modification Example 2-3 (an example in which, inside the
aperture, a wiring has a break)
[0066] 7. Modification Example 2-4 (an example in which two
apertures have oblique notches at their corners, and the two
apertures are adjacently disposed with the oblique notches
confronted with each other)
[0067] 8. Modification Example 2-5 (an example in which two
apertures have oblique notches at their sides, and the two
apertures are adjacently disposed with the oblique notches
confronted with each other)
[0068] 9. Third Embodiment (a semiconductor device; an example in
which a thickness of a solder resist layer inside an aperture is
smaller than a thickness of the solder resist layer in a region
other than the aperture out of a front surface of a substrate
body)
[0069] 10. Fourth Embodiment (a semiconductor device; an example of
an MCM (Multi Chip Module))
[0070] 11. Fifth Embodiment (a semiconductor device; an example of
sealing with a mold resin)
[0071] 12. Sixth Embodiment (a method of manufacturing a
semiconductor device; an example that involves temporarily bonding
with use of flux, and thereafter, performing a batch reflow
process)
[0072] 13. Seventh Embodiment (a method of manufacturing a
semiconductor device; an example of local reflow)
[0073] 14. Eighth Embodiment (a method of manufacturing a
semiconductor device; an example of temporarily bonding by
thermocompression)
[0074] 15. Ninth Embodiment (a method of manufacturing a
semiconductor device; an example of thermocompression, with a
temperature on tool side fixed)
[0075] 16. Tenth Embodiment (a method of manufacturing a
semiconductor device; an example in which an underfill resin is
supplied in advance on a packaging substrate)
First Embodiment
[0076] FIG. 1 schematically illustrates an overall configuration of
a semiconductor device according to a first embodiment of the
disclosure. FIG. 2 schematically illustrates a cross-sectional
configuration of the semiconductor device, taken along a line
II-II. A semiconductor device 1 may be, for example, a flip chip
semiconductor device in which a semiconductor chip 10 and a
packaging substrate 20 may be connected by a plurality of
solder-including electrodes 30. An underfill resin 40 may be
provided between the semiconductor chip 10 and the packaging
substrate 20.
[0077] Referring to FIG. 2, the semiconductor chip 10 includes a
chip body 11 that may be made of, for example, silicon (Si). An
element (undepicted) may be provided on one surface (an
element-formation surface) of the chip body 11. The semiconductor
chip 10 may be mounted on a chip mounting region 20A in a central
part of the packaging substrate 20, in a face-down posture in which
the element-formation surface 11A of the chip body 11 may be
oriented toward the packaging substrate 20. It is to be noted that
the top view of FIG. 1 depicts a chip outline 10A of the
semiconductor chip 10 in a broken line, with the semiconductor chip
10 and the underfill resin 40 omitted.
[0078] The plurality of solder-including electrodes 30 are provided
on the element-formation surface 11A of the chip body 11, as
illustrated in FIG. 2. The plurality of solder-including electrodes
30 may be provided, for example, in a peripheral part of the
element-formation surface 11A of the chip body 11 of the
semiconductor chip 10, at predetermined intervals and in a
predetermined arrangement.
[0079] Referring to FIGS. 1 and 2, the packaging substrate 20
includes a substrate body 21, for example. As illustrated in FIG.
1, the chip mounting region 20A and a plurality of wirings 50 may
be provided in a front surface (a semiconductor chip mounting
surface) 21A of the substrate body 21. A via 22 may be provided on
one end (a first end) of each of the plurality of wirings 50. As
illustrated in FIG. 2, a solder ball 23 may be provided on a rear
surface 21B of the substrate body 21. It is to be noted that the
plurality of wirings 50 are omitted in the cross-sectional view of
FIG. 2.
[0080] The substrate body 21 may have a stacked structure
including, for example, a resin substrate (undepicted), a wiring
layer made of, for example, copper (Co), and a solder resist layer
(undepicted), but there is no particular limitation on its
configurations.
[0081] The plurality of wirings 50 may be extended outward of the
substrate body 21 from a peripheral part of the chip mounting
region 20A, for example. The plurality of wirings 50 may be
disposed in parallel with one another at each side of the chip
mounting region 20A, and expanded in a radial pattern in an outer
region of the substrate body 21. It is to be noted that the
plurality of wirings 50 may be extended inward of the substrate
body 21 from the peripheral part of the chip mounting region
20A.
[0082] The via 22 may be provided between the one end (the first
end) of each of the plurality of wirings 50 and the solder ball 23,
and penetrate the substrate body 21 of the packaging substrate 20.
The via 22 may transfer each terminal from the front surface (the
semiconductor chip mounting surface) 21A of the packaging substrate
20 to the rear surface 21B (toward the solder ball 23). Each
terminal may be extended from the semiconductor chip 10, with use
of the plurality of solder-including electrodes 30 and the
plurality of wirings 50. In this embodiment, a size of the via 22
formed on the packaging substrate 20 may be larger than a size of
each of the plurality of solder-including electrodes 30. For this
reason, as illustrated in FIG. 1, each terminal may be extended
from the semiconductor chip 10 with use of the plurality of
solder-including electrodes 30, and extracted to a peripheral part
of the substrate body 21 with use of the plurality of wirings 50,
on the packaging substrate 20. This allows for widening of an
inter-wiring pitch of the plurality of wirings 50. Furthermore,
each terminal may be extracted toward the solder ball 23 on the
packaging substrate 20 with use of the via 22.
[0083] The solder ball 23 may perform signal input into and output
from the semiconductor chip 10, and perform power supply to the
semiconductor chip 10.
[0084] The underfill resin 40 may protect bonding parts between the
plurality of solder-including electrode 30 and the plurality of
wirings 50, and be filled between the semiconductor chip 10 and the
packaging substrate 20. In one preferred example, fillers may be
dispersed in the underfill resin 40, in order to adjust a thermal
expansion coefficient. As the fillers, for example, silicon oxide
in a spherical shape may be used. In one desired example, the
thermal expansion coefficient of the underfill resin 40 may be
adjusted to, for example, approximately 10 ppm/.degree. C. to 50
ppm/.degree. C. both inclusive.
[0085] FIG. 3 illustrates, in an enlarged manner, part of the
semiconductor device 1 illustrated in FIG. 1. Specifically, FIG. 3
illustrates a plan configuration of the two adjacent wirings 50
(50A and 50B) in vicinity of the peripheral part of the chip
mounting region 20A. It is to be noted that the semiconductor chip
10 and the underfill resin 40 are omitted in the top view of FIG. 3
for an easier understanding, but the semiconductor chip 10 may be
disposed in a region leftward of the chip outline 10A of the
semiconductor chip 10 denoted by a broken line.
[0086] The packaging substrate 20 may include a solder resist layer
24, as well as the plurality of wirings 50, on the front surface
21A of the substrate body 21. The solder resist layer 24 may be
made of, for example, a negative photosensitive permanent resist
material.
[0087] The solder resist layer 24 is provided as a continuous layer
on the front surface 21A of the substrate body 21 and the plurality
of wirings 50, and has an aperture 60 on each of the plurality of
wirings 50. In one specific example, each of the plurality of
wirings 50 may have, for example, a land 57 having a circular
shape, on another end (a second end). The aperture 60 may be
provided, for example, in a circular shape on the land 57. FIG. 3
depicts, for example, the two apertures 60A and 60B provided on the
two wirings 50A and 50B. Inside the aperture 60A, the wiring 50A
and the solder-including electrode 30A may be bonded together.
Inside the aperture 60B as well, the wiring 50B and the
solder-including electrode 30B may be bonded together. Thus, the
plurality of solder-including electrodes 30 and the plurality of
wirings 50 may be bonded together inside the apertures 60, to form
connection between the semiconductor chip 10 and the packaging
substrate 20. It is to be noted that in FIG. 3, a region in which
the solder resist layer 24 is provided is represented by a lightly
dotted region.
[0088] As described, the solder resist layer 24 is provided as the
continuous layer, and has the partial apertures 60. This makes it
possible to ensure insulation between the plurality of adjacent
wirings 50. Accordingly, even when the two wirings 50A and 50B are
arranged at a small pitch of about 40 .mu.m, it is possible to
reduce possibility that the solder-including electrode 30A
connected to the wiring 50A comes into contact with the adjacent
wiring 50B. This allows for suppression of occurrence of a short
circuit.
[0089] Moreover, because the solder resist layer 24 has the partial
apertures 60, the solder resist layer 24 is continuous or undivided
on the packaging substrate 20. Hence, it is possible to prevent the
plurality of wirings 50 from peeling off, and to prevent the solder
resist layer 24 from peeling off
[0090] FIG. 4 illustrates a cross-sectional configuration of the
aperture 60A, taken along a line IV-IV of FIG. 3. It is to be noted
that the aperture 60B may have a similar configuration as well. The
aperture 60 may allow part of an upper surface 53 of the wiring 50
inside the aperture 60 to be exposed, for example. Each of the
plurality of solder-including electrodes 30 may cover an exposed
part of the wiring 50 inside the aperture 60.
[0091] Each of the plurality of solder-including electrodes 30
includes, for example, a columnar metal layer 31 and a solder layer
32, in the order named from side on which the chip body 11 is
disposed. The columnar metal layer 31 is made of a metal having a
higher melting point than a melting point of solder that
constitutes the solder layer 32. This allows for limited use of the
solder material to a tip part of the solder-including electrode 30,
as compared to solder bump connection as used in the existing C4
technique. Accordingly, the diameter d of the solder-including
electrode 30 may be substantially limited to a diameter of the
columnar metal layer 31, even when the solder melts into a
spherical shape due to surface tension. It is therefore possible to
reduce an inter-electrode pitch of the plurality of
solder-including electrodes 30.
[0092] In one preferred example, the columnar metal layer 31 may be
made of copper (Cu), or include a stacked film of copper (Cu) and
nickel (Ni), for example. The solder layer 32 may be made of, for
example, tin (Sn) or Sn--Ag.
[0093] The columnar metal layer 31 including copper makes it
possible to enhance heat dissipation of the semiconductor device 1
even more, since copper has optimal thermal conductivity. Moreover,
copper and the solder material form an alloy having an optimal
strength. This makes it possible to provide an electrode structure
having more optimal connection strength.
[0094] With the solder layer 32 made of tin or Sn--Ag, copper may
disperse inside the solder layer 32 when the columnar metal layer
31 includes copper. An Sn--Cu alloy may be formed when the solder
layer 32 is made of tin, while an Sn--Ag--Cu alloy may be formed
when the solder layer 32 is made of Sn--Ag. These are known to have
stable and optimal mechanical characteristics as solder materials,
and make it possible to provide a connection structure having more
optimal strength and more optimal reliability.
[0095] In one preferred alternative example, the columnar metal
layer 31 may be made of copper (Cu), or include a stacked film of
copper (Cu) and nickel (Ni), for example. The solder layer 32 may
be made of, for example, indium (In) or In--Ag. In this case, the
description given above may apply to the columnar metal layer 31.
Moreover, the solder layer 32 made of indium or In--Ag allows for
lowering of the melting point. This makes it possible to reduce
thermal stress generated during an assembly process, and to provide
a structure having a more optimal yield and more optimal
reliability.
[0096] In one preferred example, a height H31 of the columnar metal
layer 31 may be larger than a height H32 of the solder layer 32.
This makes it possible to increase a gap G between the
semiconductor chip 10 and the packaging substrate 20, in spite of a
decrease in an amount of the solder, by the height H31 of the
columnar metal layer 31. It is therefore possible to form the
plurality of solder-including electrodes 30 at the narrower pitch,
while allowing for easier injection of the underfill resin 40.
[0097] In one preferred example, the aperture 60 may be filled with
the solder layer 32. If a minute aperture that is not filled with
the solder should remain inside the aperture 60, it is difficult to
fill the minute aperture with the underfill resin 40 in
post-processes, leading to possibility that the minute aperture may
become a void. In this case, there may be possibility that air
inside the void may expand to cause a bonding failure in a ball
attachment or in a reflow process in secondary mounting, or
possibility that the molten solder may flow along the void to cause
the short circuit between the adjacent wirings 50. Filling the
aperture 60 with the solder layer 32 makes it possible to suppress
the occurrence of the void, or the bonding failure or the short
circuit due to the void, and to prevent the yield or the
reliability from being lowered.
[0098] In one preferred example, a volume of the solder layer 32
may be larger than a volume of the aperture 60. This makes it
possible to surely fill the aperture 60 with the solder layer 32.
Moreover, with the volume of the solder layer 32 larger than the
volume of the aperture 60, it is possible to provide a sufficient
amount of the solder, and to allow the bonding part between the
solder-including electrode 30 and the wiring 50 to have an optimal
shape. Accordingly, the bonding part between the solder-including
electrode 30 and the wiring 50 may be kept from having a distorted
shape, or from having a partly constricted shape. Hence, it is
possible to avoid concentration of stress to the solder layer 32,
leading to higher mechanical strength of the bonding part.
[0099] Moreover, in this embodiment, the plurality of
solder-including electrodes 30 each have a function of serving as a
gap control electrode that controls the gap G between the
semiconductor chip 10 and the packaging substrate 20. In other
words, the plurality of solder-including electrodes 30 each include
an overlap region OL where the columnar metal layer 31 and the
solder resist layer 24 overlap each other, along all (a perimeter)
of an aperture end (outline) 61 of the aperture 60. Hence, in the
semiconductor device 1, it is possible to stably control the gap G
between the semiconductor chip 10 and the packaging substrate 20,
and to suppress the short circuit between the adjacent wirings
50.
[0100] The following effects may be obtained by adopting such an
arrangement of the columnar metal layer 31 and the aperture 60.
Whatever technique is adopted in connecting the semiconductor chip
10 to the packaging substrate 20, it is possible to avoid direct
contact between the columnar metal layer 31 and the wiring 50. In
other words, the gap G between the semiconductor chip 10 and the
packaging substrate 20 may be self-alignedly adjusted to a value
equal to or higher than the height H31 of the columnar metal layer
31. Accordingly, a distance between the columnar metal layer 31 and
the wiring 50 may be restrained from becoming excessively small,
and resulting in the short circuit between the solder layer 32
forced out of the aperture 60 and the nearby solder-including
electrode 30. It is therefore possible to produce, with a high
yield, the flip chip semiconductor device 1 in which an
inter-electrode pitch of the plurality of solder-including
electrodes 30 is narrowed. Moreover, it is possible to provide the
stable gap G, without providing an extra structure such as a spacer
for gap adjustment.
[0101] In one preferred example, the diameter d of the columnar
metal layer 31 may be larger than a width (diameter) W of the
aperture 60, along part or all of the aperture end 61 of the
aperture 60. In this embodiment, the width (diameter) d of the
columnar metal layer 31 may be, for example, 90 .mu.m. A diameter
.phi.57 of the land 57 may be, for example, 110 .mu.m. The width
(diameter) W of the aperture 60 may be, for example, 80 .mu.m.
[0102] It is to be noted that description in this embodiment is
given on a case in which, as illustrated in FIG. 3, the
solder-including electrode 30 and the aperture 60 may have a planar
positional relationship of a concentric circular shape, and the
solder-including electrode 30 may include the overlap region OL
along all of the aperture end 61 of the aperture 60. However, the
plurality of solder-including electrodes 30 each may include the
overlap region OL where the columnar metal layer 31 and the solder
resist layer 24 overlap each other, along part of the aperture end
61 of the aperture 60. This case is described later in a second
embodiment.
[0103] A pad 13 made of aluminum (Al) may be provided on the
element-formation surface 11A of the chip body 11 of the
semiconductor chip 10. The columnar metal layer 31 may be
electrically connected to the pad 13 through a conductive thin film
and a barrier film in the order named from side on which the
columnar metal layer 31 is disposed, but the conductive thin film
and the barrier film are omitted in FIG. 4. For example, copper
(Cu) as the conductive thin film, and for example, TiW as the
barrier film may be formed by sputtering. A passivation film 14 may
cover a region other than a region in which the pad 13 is provided,
out of the element-formation surface 11A of the chip body 11 of the
semiconductor chip 10. It is to be noted that not only the pad 13
and the passivation film 14 but also layers such as wiring layers
and diffusion layers may be formed in the semiconductor chip 10,
but the layers such as the wiring layers and the diffusion layers
are omitted in FIG. 4.
[0104] The plurality of wirings 50 may be wirings on an outermost
layer of the packaging substrate 20. It is to be noted that FIG. 4
depicts a single-layer structure of an insulating layer 21C
provided directly under the plurality of wirings 50, as the
substrate body 21 of the packaging substrate 20. However, the
substrate body 21 may be a stacked structure including a layer or
layers other than the insulating layer 21C.
[0105] In one preferred example, each of the plurality of wirings
50 may include a metal wiring layer 51 and a surface coating 52.
The metal wiring layer 51 may be made of copper (Cu) as a principal
component. The surface coating 52 may cover a region exposed in the
aperture 60, out of a surface of the metal wiring layer 51.
Providing the surface coating 52 contributes to enhanced solder
wettability, and promotes wetting and spreading of the solder over
the surface of the metal wiring layer 51. This results in easier
wetting and spreading of the solder over the whole exposed region
of the wiring 50 inside the aperture 60, when the aperture 60 has a
planar shape elongated in a lengthwise direction DL of the wiring
50 inside the aperture 60 as described later in the second
embodiment. It is therefore possible to more surely encourage an
effect of enhancing the bonding strength.
[0106] In one preferred example, the surface coating 52 may
include, for example, an Ni--Au plating layer or an Ni--Pd--Au
plating layer. Because nickel of the surface coating 52 and the
solder layer 32 may form an alloy layer, the wiring 50 may be
prevented from excessively forming an alloy layer with the solder,
being thinned by the solder, and being dissipated and disconnected.
The solder may be prevented from intruding into between the wiring
50 and the insulating layer 21C of the packaging substrate 20,
causing lower adhesion strength of the wiring 50, and causing the
wiring 50 to peel off and to be disconnected. Moreover, the solder
layer 32 may react with gold of the surface coating 52, to improve
wettability and to allow for prevention of a failure in bonding to
the wiring 50. Also, wetting and spreading of the solder along the
exposed wiring 50 makes it possible to steadily increase area of
the bonding part between the solder-including electrode 30 and the
wiring 50. In particular, adoption of non-electrolytic plating
makes it possible to suppress variations in thickness of the
surface coating 52, and to provide a structure having higher
reliability of the bonding part.
[0107] A method of manufacturing the semiconductor device 1 is
described in sixth to tenth embodiments.
[0108] In the semiconductor device 1, the plurality of
solder-including electrodes 30 each have the function of serving as
the gap control electrode, and each include the overlap region OL
where the columnar metal layer 31 and the solder resist layer 24
overlap each other, along all or part of the aperture end 61 of the
aperture 60. The gap G between the semiconductor chip 10 and the
packaging substrate 20 may be thereby defined as a value equal to
or higher than the height H31 of the columnar metal layer 31.
Accordingly, the gap G between the columnar metal layer 31 and the
wiring 50 may be restrained from becoming excessively small, and
causing the solder interposed between the columnar metal layer 31
and the wiring 50 to be expelled. This may contribute to the
suppression of the short circuit between the adjacent wirings 50
due to the solder thus expelled. Moreover, a volume of the solder
layer 32 may be small as compared to a case of the existing C4
connection, but even when the gap G between the semiconductor chip
10 and the packaging substrate 20 becomes excessively wide, a
solder shape of the bonding part may be restrained from being
distorted due to shortage in an amount of the solder. Thus, a
breakage of the solder due to concentration of stress or fatigue
may be restrained.
[0109] As described, in this embodiment, the plurality of
solder-including electrodes 30 are each provided with the function
of serving as the gap control electrode, and the overlap region OL
where the columnar metal layer 31 and the solder resist layer 24
overlap each other is provided along part or all of the aperture
end 61 of the aperture 60. Hence, it is possible to stably control
the gap G between the semiconductor chip 10 and the packaging
substrate 20, and to suppress the short circuit between the
adjacent wirings 50. It is therefore possible to suppress the short
circuit due to shrinkage of the inter-wiring pitch of the plurality
of wirings 50, or due to shrinkage of the inter-electrode pitch of
the plurality of solder-including electrodes 30, when high-density
flip chip connection is performed. Moreover, it is possible to
suppress lowering of reliability of the bonding part due to a
decrease in size of the plurality of solder-including electrodes
30, and to provide a product with high reliability or a high yield.
Furthermore, it is also possible to provide such a product at even
lower costs, with higher functionalization by increasing the number
of connection terminals.
[0110] It is to be noted that description in the first embodiment
is given on a case in which the plurality of solder-including
electrodes 30 each serve as the gap control electrode. The solder
resist layer 24 is, however, less liable to be deformed by the
columnar metal layer 31 pressed against the solder resist layer 24.
Accordingly, the plurality of solder-including electrodes 30 may
include at least one gap control electrode, making it possible to
obtain effects similar to those of the first embodiment.
[0111] Moreover, in one preferred example, the plurality of
solder-including electrodes 30 may include a plurality of gap
control electrodes, and at least one of the plurality of gap
control electrodes may be disposed at each side of the rectangular
semiconductor chip 10, in consideration of a tilt of the
semiconductor chip 10 when the semiconductor chip 10 is
pressure-bonded. Furthermore, the plurality of solder-including
electrodes 30 each may have the function of serving as the gap
control electrode as in the first embodiment, making it possible to
obtain the effects more reliably, in consideration of variations in
height of the plurality of solder-including electrodes 30 as
well.
Modification Example 1-1
[0112] In addition, description in the forgoing first embodiment is
given on a case where the overlap region OL where the columnar
metal layer 31 and the solder resist layer 24 overlap each other
may be provided, by allowing the diameter d of the columnar metal
layer 31 to be larger than the width (diameter) W of the aperture
60. However, for example, as illustrated in FIG. 5, a center C31 of
the columnar metal layer 31 may be out of alignment with a center
C60 of the aperture 60. In this case as well, it is possible to
provide the overlap region OL where the columnar metal layer 31 and
the solder resist layer 24 overlap each other, and to obtain
effects similar to those of the forgoing first embodiment. It is to
be noted that this modification example is not limited to the first
embodiment. It is possible to combine this modification example
with any of second to tenth embodiments or any of modification
examples to be described below.
Second Embodiment
[0113] FIG. 6 illustrates, in an enlarged manner, part of a
semiconductor device 2 according to the second embodiment of the
disclosure. Specifically, FIG. 6 illustrates a plan configuration
of the two adjacent wirings 50 (50A and 50B) in the vicinity of the
peripheral part of the chip mounting region 20A. It is to be noted
that the semiconductor chip 10 and the underfill resin 40 are
omitted in the top view of FIG. 6 for an easier understanding, but
the semiconductor chip 10 may be disposed in the region leftward of
the chip outline 10A of the semiconductor chip 10 denoted by the
broken line.
[0114] In this embodiment, the aperture 60 may have a planar shape
of a rectangle or substantially rectangle elongated in the
lengthwise direction DL of the wiring 50 inside the aperture 60. A
length L of the aperture 60 may be adjusted in accordance with the
thermal expansion coefficient of the packaging substrate 20. Hence,
in the semiconductor device 2, it is possible to alleviate
influence of positional deviation between the aperture 60 and the
solder-including electrode 30, and to suppress the short circuit
between the adjacent wirings 50. Otherwise, the semiconductor
device 2 according to this embodiment may have similar
configurations, workings, and effects to those of the semiconductor
device 1 according to the foregoing first embodiment. Description
is therefore given with corresponding components denoted by same
reference characters.
[0115] The solder resist layer 24 is provided as a continuous layer
on the front surface 21A of the substrate body 21 and the plurality
of wirings 50, and has the aperture 60 on each of the plurality of
wirings 50. In one specific example, each of the plurality of
wirings 50 may have, for example, a constant width W50. The
aperture 60 may be provided, for example, in a rectangular or
substantially rectangular shape on another end of each of the
plurality of wirings 50. FIG. 6 depicts, for example, the two
apertures 60A and 60B provided on the two wirings 50A and 50B.
Inside the aperture 60A, the wiring 50A and the solder-including
electrode 30A may be bonded together. Inside the aperture 60B as
well, although undepicted, the wiring 50B and the solder-including
electrode 30B may be bonded together. Thus, the plurality of
solder-including electrodes 30 and the plurality of wirings 50 may
be bonded together inside the apertures 60, to form connection
between the semiconductor chip 10 and the packaging substrate 20.
It is to be noted that in FIG. 6, a region in which the solder
resist layer 24 is provided is represented by a lightly dotted
region.
[0116] In one preferred example, as illustrated in FIG. 6, the
adjacent apertures 60A and 60B may be arranged at alternatively
deviated positions with respect to the lengthwise direction DL of
the plurality of wirings 50 (a so-called staggered arrangement), in
order to reduce the inter-wiring pitch P50 between the plurality of
wirings 50.
[0117] FIG. 7 illustrates a cross-sectional configuration of the
aperture 60A, taken along a line VII-VII of FIG. 6. It is to be
noted that the aperture 60B may have a similar configuration as
well. The aperture 60 may allow the upper surface 53 and all in a
heightwise direction of side surfaces 54 of the wiring 50 inside
the aperture 60 to be exposed, for example. Each of the plurality
of solder-including electrodes 30 may cover the exposed part of the
wiring 50 inside the aperture 60 (the part exposed in the aperture
60, out of the upper surface 53 and the side surfaces 54 of the
wirings 50). In other words, the aperture 60 may be provided to
allow the upper surface 53 and the side surfaces 54 of the wiring
50 inside the aperture 60 to be exposed. The aperture end 61 of the
aperture 60 may be positioned outward of the side surfaces 54 of
the wiring 50 inside the aperture 60. The diameter d of the
solder-including electrode 30 may be larger than the width W50 of
the wiring 50. The solder-including electrode 30 may be connected
to the wiring 50, so as to envelope or surround the wiring 50.
[0118] In this way, area of connection between the solder-including
electrode 30 and the wiring 50 may be enlarged, making it possible
to form the bonding part between the solder-including electrode 30
and the wiring 50, not in a two-dimensional shape but in a
three-dimensional shape. Consequently, it is possible to suppress
an intermetallic compound generated in the bonding part from being
destroyed, even when thermal stress due to the difference in the
thermal expansion coefficients of the semiconductor chip 10 and the
packaging substrate 20 is applied to the bonding part. The thermal
stress may be caused by heating in mounting of the semiconductor
chip 10, a reflow process in mounting in an assembly line, or heat
generation during device operation. Hence, it is possible to
enhance reliability.
[0119] In one preferred example, each of the plurality of
solder-including electrodes 30 may include, for example, the
columnar metal layer 31 and the solder layer 32, in the order named
from side on which the chip body 11 is disposed, as with the first
embodiment. The columnar metal layer 31 and the solder layer 32 may
be configured similarly to those in the first embodiment.
[0120] In addition, the plurality of solder-including electrodes 30
each may have the function of serving as the gap control electrode
that controls the gap G between the semiconductor chip 10 and the
packaging substrate 20, as with the first embodiment. In other
words, the plurality of solder-including electrodes 30 may have the
overlap region OL where the columnar metal layer 31 and the solder
resist layer 24 overlap each other, along part of the aperture end
61 of the aperture 60, as illustrated in FIG. 7. Hence, in the
semiconductor device 2, it is possible to stably control the gap G
between the semiconductor chip 10 and the packaging substrate 20,
and to suppress the short circuit between the adjacent wirings 50,
as with the first embodiment.
[0121] The pad 13 made of aluminum (Al) and the passivation film 14
may be provided on the element-formation surface 11A of the chip
body 11 of the semiconductor chip 10, as with the first
embodiment.
[0122] In one preferred example, each of the plurality of wirings
50 may include the metal wiring layer 51 and the surface coating
52, as with the first embodiment. The metal wiring layer 51 may be
made of copper (Cu) as the principal component. The surface coating
52 may cover the region exposed in the aperture 60, out of the
surface of the metal wiring layer 51. In one preferred example, the
constituent material of the surface coating 52 may be similar to
that in the first embodiment.
[0123] FIG. 8 illustrates a cross-sectional configuration of the
aperture 60A, taken along a line VIII-VIII of FIG. 6. It is to be
noted that the aperture 60B may have a similar configuration. As
illustrated in FIGS. 6 and 8, the aperture 60 may have the planar
shape elongated in the lengthwise direction DL of the wiring 50
inside the aperture 60. The length L of the aperture 60 may be
adjusted in accordance with the thermal expansion coefficient of
the packaging substrate 20. Hence, in the semiconductor device 2,
it is possible to alleviate the influence of the positional
deviation between the aperture 60 and the solder-including
electrode 30, and to suppress the short circuit between the
adjacent wirings 50.
[0124] Possible effects obtained by the aperture 60 elongated in
the lengthwise direction DL of the wiring 50 inside the aperture 60
as described may be as follows. In order to connect the
solder-including electrode 30 to the wiring 50, heating may be
carried out to melt the solder. At this occasion, the aperture 60
of the solder resist layer 24 and the solder-including electrode 30
on the semiconductor chip 10 may be deviated from setting values,
i.e., their relative positions at room temperature, because of the
difference between the thermal expansion coefficients of the
semiconductor chip 10 and the packaging substrate 20 including the
wiring 50 and the insulating layer 21C. Because the thermal
expansion coefficient of the packaging substrate 20 is generally
larger than the thermal expansion coefficient of the semiconductor
chip 10, there may be the positional deviation as illustrated in
FIG. 9 at a temperature at which the solder melts.
[0125] In this embodiment, the aperture 60 may have the planar
shape elongated in the lengthwise direction DL of the wiring 50
inside the aperture 60. The length L of the aperture 60 may be
adjusted in accordance with the thermal expansion coefficient of
the packaging substrate 20. This makes it possible to suppress the
solder layer 32 from running on the solder resist layer 24 as
illustrated in FIG. 9 to cause occurrence of the short circuit with
the adjacent solder-including electrode 30B. Moreover, the
plurality of wirings 50 may be arranged to be extended outward of
the substrate body 21 from the peripheral part of the chip mounting
region 20A, as illustrated in FIG. 1, so as to widen the
inter-wiring pitch of the plurality of wirings 50 to the pitch of
the vias 22. This arrangement of the plurality of wirings 50 may be
combined with the aperture 60 elongated along the lengthwise
direction DL of the wiring 50 inside the aperture 60, to produce
the effects of the suppression of the short circuit as
described.
[0126] Furthermore, enlarging the aperture 60 selectively along a
specific direction, i.e., selectively along the lengthwise
direction DL of the wiring 50 inside the aperture 60 makes it
possible to provide a structure adapted to the positional deviation
in heating, while maintaining the effects of the suppression of the
short circuit without widening the pitch of the plurality of
wirings 50.
[0127] In addition, it is possible to increase area of a region in
which the solder layer 32 and the wiring 50 form an alloy layer.
This leads to higher bonding strength, and enhancement in the yield
and the reliability.
[0128] It is to be noted that in FIGS. 7 and 8, the width W50 of
each of the wirings 50A and 50B may be, for example, 15 .mu.m. The
inter-wiring pitch P50 between the wirings 50A and 50B may be, for
example, 40 .mu.m. The height H50 of the wirings 50A and 50B may
be, for example, 15 .mu.m. The width W of the aperture 60 may be,
for example, 40 .mu.m, while the length L of the aperture 60 may
be, for example, 60 .mu.m. The height H31 of the columnar metal
layer 31 may be, for example, 40 .mu.m. The columnar metal layer 31
may have a shape of, for example, a circular column, and the
diameter d may be, for example, 45 .mu.m. Because the diameter d of
the columnar metal layer 31 is larger than the width W of the
aperture 60 as described above, it is possible to stably control
the gap G between the semiconductor chip 10 and the packaging
substrate 20, and to suppress the short circuit between the
adjacent wirings 50, as described in the first embodiment. The
height H32 of the solder layer 32 may be, for example, 18 .mu.m.
The gap between the semiconductor chip 10 and the packaging
substrate 20 (a distance from the passivation layer 13 of the
semiconductor chip 10 to the solder resist layer 24 of the
packaging substrate 20) may be, for example, at least 40 .mu.m or
more.
[0129] In one preferred example, the length L of the aperture 60
may satisfy, for example, the following Expression 1.
L>(a-3.5)*D*(T-25)*10.sup.-6+d Expression 1
[0130] (In Expression 1, L denotes the length (mm) of the aperture
60, a denotes an equivalent thermal expansion coefficient
(ppm/.degree. C.) of the packaging substrate 20, D denotes a
distance (mm) from a center of the packaging substrate 20 to the
center of the aperture 60, T denotes a melting point (.degree. C.)
of the solder, and d denotes the diameter of the solder-including
electrode 30.)
[0131] In the following, description is given on more details of
Expression 1.
[0132] It is known that the thermal expansion coefficient of the
packaging substrate 20 may be roughly substituted by the equivalent
thermal expansion coefficient a that may be defined by the
following Expression 2 (reference: "Thermophysical Properties
Handbook", Japan Society of Thermophysical Properties, 1990, pp.
285-289).
a=.SIGMA.(thickness*elastic modulus*CTE)/.SIGMA.(thickness*elastic
modulus) Expression 2
[0133] Here, ".SIGMA." denotes summing of values regarding all
materials that constitute the packaging substrate 20. CTE is a
thermal expansion coefficient of each material. When the solder
that constitutes the solder layer 32 is Sn--Ag, the melting point
is 221.degree. C. Whatever bonding process is used, at least the
packaging substrate 20 is heated to a temperature near the melting
point of the solder. Accordingly, an amount of the positional
deviation .DELTA.L from a room-temperature state between the
packaging substrate 20 and the solder layer 32 may be defined by
the following Expression 3, with the room temperature assumed to be
25.degree. C.
.DELTA.L=(a-3.5)*(221-25)*10.sup.-6*D Expression 3
[0134] Here, "D" denotes the distance from the center of the
packaging substrate 20 to the bonding part (the center of the
aperture 60). 3.5 is a thermal expansion coefficient of silicon
(Si) that is a principal constituent material of the semiconductor
chip 10. Accordingly, the length L of the aperture 60 may be at
least a value equal to or larger than as given by the following
Expression 4. This makes it possible to allow most of the solder to
go into the aperture 60 even when the solder is heated in solder
bonding.
L>(a-3.5)*(221-25)*D*10.sup.6+d Expression 4
[0135] Here, "d" denotes the diameter of each of the plurality of
solder-including electrodes 30, i.e., the diameter of the columnar
metal layer 31. In a desirable example, a maximum of the length L
of the aperture 60 may be adjusted so as to allow the aperture 60
to be filled with the solder layer 32 as described above, in
consideration of a volume of plating of the solder layer 32, the
width W of the aperture 60, and the width W50 of the wiring 50.
[0136] For example, let us calculate the length L of the aperture
60 on an assumption that the packaging substrate 20 is manufactured
with a configuration as summarized in Table 1.
TABLE-US-00001 TABLE 1 Elastic Material Thickness modulus CTE used
(.mu.m) (GPa) (ppm) Solder resist AUS703 20 9 23 L1: Wiring layer
Cu 15 120 16 Insulating layer GX92 35 5 39 L2: Cu wiring layer Cu
25 120 16 Core insulating layer E700GR 800 33 8 L3: Cu wiring layer
Cu 25 120 16 Insulating layer GX92 35 5 39 L4: Cu wiring layer Cu
15 120 16 Solder resist AUS703 20 9 23
[0137] The packaging substrate may be a build-up four-layer
substrate, and include an epoxy material including glass cloth
(Hitachi Chemical Company, Ltd.: 700GR) as a core material, an ABF
film material (Ajinomoto Fine-Techno Co., Inc.: GX92) as a build-up
material, a solder resist (Taiyo Ink Mfg. Co. Ltd.: AUS703), and
wiring layers made of copper. A thickness of the core material may
be 800 .mu.m. A thickness of the build-up layer may be 35 .mu.m. A
solder resist thickness may be 20 .mu.m. A thickness of a wiring
layer as a surface layer may be 15 .mu.m. A thickness of the wiring
layer as a core layer may be 25 .mu.m. An elastic modulus and a
thermal expansion coefficient (CTE) of each material may be as
summarized in Table 1. Regarding a position at which the columnar
metal layer 31 is disposed, D may be equal to approximately 7.06 mm
(D=approximately 7.06 mm), when considering angles (corners) at
which thermal expansion becomes largest, on an assumption that, for
example, the pads 13 are arranged in an area of 10 mm.quadrature..
The pads 13 may serve as I/O pads of the semiconductor chip 10.
[0138] With use of these parameters, the equivalent thermal
expansion coefficient a may be given by Expression 2 as
approximately 10.5 ppm/.degree. C. Assume that a temperature
applied in a process of connecting the semiconductor chip 10 to the
plurality of wirings 50 with use of the solder layer 32 is 221
degrees, i.e., the melting point of the Sn--Ag based solder. As a
result, a maximum of the amount of the positional deviation AL
given by Expression 3 may be 9.75 .mu.m. Here, in one desirable
example, from Expression 4, the length L of the aperture 60 may be
at least 49.75 .mu.m or more, because the diameter d of the
columnar metal layer 31 is 40 .mu.m. Thus, the length L of the
aperture 60 may be designed to be, for example, 55 .mu.m.
[0139] The volume of the aperture 60 may be calculated as 31625
.mu.m.sup.3, exclusive of the volume occupied by the wiring 50.
Accordingly, when the solder-including electrode 30 is designed to
allow the volume of the solder layer 32 to be larger than this
value, the thickness of plating of the solder layer 32 may be 25.2
.mu.m or more. Because there are variations in an actual thickness
of plating, the design of the solder-including electrode 30 may be
carried out in consideration of the variations.
[0140] It is to be noted that the thickness of plating of the
solder layer 32 may be reduced, as described later in a third
embodiment, by stopping development halfway before the solder
resist layer 24 is removed to allow the insulating layer 21C of the
packaging substrate 20 to be exposed.
[0141] A method of manufacturing the semiconductor device 2 is
described in the sixth to tenth embodiments.
[0142] In the semiconductor device 2, the aperture 60 of the solder
resist layer 24 may have the planar shape elongated in the
lengthwise direction DL of the wiring 50 inside the aperture 60.
The length L of the aperture 60 may be adjusted in accordance with
the thermal expansion coefficient of the packaging substrate 20.
Accordingly, in heating for the solder bonding during the assembly
process, there is little possibility that the solder layer 32 may
run on the solder resist layer 24 even in a case with the
positional deviation between the aperture 60 and the
solder-including electrode 30 due to the difference in the thermal
expansion coefficients of the semiconductor chip 10 and the
packaging substrate 20. Thus, influence of the positional deviation
between the aperture 60 and the solder-including electrode 30 is
alleviated, leading to the suppression of the short circuit between
the adjacent wirings 50.
[0143] As described, in this embodiment, the aperture 60 of the
solder resist layer 24 may have the planar shape elongated in the
lengthwise direction DL of the wiring 50 inside the aperture 60.
The length L of the aperture 60 may be adjusted in accordance with
the thermal expansion coefficient of the packaging substrate 20.
Hence, it is possible to alleviate the influence of the positional
deviation between the aperture 60 and the solder-including
electrode 30, leading to the suppression of the short circuit
between the adjacent wirings 50. In particular, this embodiment is
suitable for a case in which a plurality of functions are
synthesized in the single semiconductor chip 10 with an increase in
a chip size, or a case in which the diameter d of the
solder-including electrode 30 is reduced and the solder-including
electrodes 30 are connected to the wirings 50 at a fine pitch.
[0144] Moreover, the aperture 60 may have the planar shape
elongated in the lengthwise direction DL of the wiring 50 inside
the aperture 60. This makes it possible to increase the area of the
exposed part from the solder resist layer 24, of the wiring 50 as a
connection target, without allowing the surface of the adjacent
wiring 50 to be exposed. As a result, it is possible to enlarge the
bonding area between the solder-including electrode 30 and the
wiring 50, and to increase the mechanical strength of the bonding
part. In other words, it is possible to suppress destruction due to
the thermal stress generated by heating in the bonding process, to
improve the mechanical strength against temperature cycles applied
in the operation of the semiconductor chip 10, and to provide the
flip chip semiconductor device 2 having the high yield or the high
reliability.
[0145] Furthermore, the solder resist layer 24 is provided as the
continuous layer on the front surface of the substrate body 21 and
the plurality of wirings 50, and has the partial aperture 60 on
each of the plurality of wirings 50. Hence, it is possible to
prevent the solder resist layer 24 from peeling off from the
plurality of wirings 50, so as not to lose a function of the
suppression of the short circuit or a function of wiring
protection.
[0146] In addition, the solder resist layer 24 is provided as the
continuous layer. This allows the solder resist layer 24 to be
interposed between the bonding part of the solder-including
electrode 30 and the wiring 50, and the adjacent wiring 50. It is
therefore possible to suppress the short circuit even when the
inter-wiring pitch P50 is reduced. Hence, it is possible to reduce
the inter-wiring pitch P50, and to provide a more highly densified
connection structure between the semiconductor chip 10 and the
packaging substrate 20. As a result, it is possible to provide, at
lower costs, a flip chip structure adapted to higher
functionalization of the semiconductor chip 10 or widening of a
band of an interface.
[0147] Furthermore, the solder resist layer 24 is provided as the
continuous layer. This makes it possible to prevent the solder from
excessively wetting and spreading along the wiring 50, causing
shortage of the volume of the solder, causing the distorted shape
of the bonding part of the solder-including electrode 30 and the
wiring 50, and causing lowered mechanical strength.
[0148] In addition, in this embodiment, the plurality of wirings 50
may be extended outward of the substrate body 21 from the
peripheral part of the chip mounting region 20A, and disposed in
parallel with one another at each side of the chip mounting region
20A. Hence, it is possible to directly extend the plurality of
wirings 50 to an outer part of the packaging substrate 20 from the
bonding parts of the solder-including electrodes 30 and the
plurality of wirings 50. Also, pre-solder formation may be
eliminated. It is also unnecessary to miniaturize the wirings 50
and to form the wirings 50 between lands, or to form wirings to
lower layers from lands through vias, as in the existing C4
technique. This makes it possible to remarkably reduce substrate
costs.
[0149] Furthermore, the aperture 60 may allow the upper surface 53
and part or all in the heightwise direction of the side surfaces 54
of the wiring 50 inside the aperture 60 to be exposed. This makes
it possible to increase the area of the region in which the solder
layer 32 and the wiring 50 form the alloy layer. In addition, the
alloy layer thus generated may extend not only two-dimensionally as
in the existing land-solder connection, but also
three-dimensionally including a thicknesswise direction of the
wiring 50. This makes it possible to provide a structure having
higher bonding strength.
[0150] In addition, the length L of the aperture 60 may be set on
the basis of Expression 1. Hence, it is possible to prevent the
solder layer 32 from running on the solder resist layer 24 and
causing the short circuit between the adjacent wirings 50, in
heating to the temperature near the melting point of the solder in
bonding of the solder-including electrode 30 and the wiring 50.
[0151] Regarding this, similar effects may be obtained not only
during a flip chip bonding process of the semiconductor chip 10 and
the packaging substrate 20, but also a post-process of reflow for
BGA ball attachment and a heating process in mounting on a mother
board on the assembly line. In other words, when the semiconductor
device 2 is heated to a temperature equal to or higher than the
melting point of the solder, the semiconductor chip 10 and the
packaging substrate 20 each may thermally expand. Furthermore, the
underfill resin 40 may be heated above a glass transition
temperature and soften. Also, the solder layer 32 may melt.
Accordingly, there is possibility that the columnar metal layer 31
may protrude from the aperture 60 and be positioned on the solder
resist layer 24, with the solder layer 32 melting. Part of the
solder layer 32 may move together with the columnar metal layer 31
and run over the solder resist layer 24. This may cause possibility
of the short circuit with the adjacent wiring 50. Even if no short
circuit is caused, there may be possibility of destruction due to
thermal stress, during a cooling process, because of the distorted
shape of the bonding part of the solder-including electrode 30 and
the wiring 50.
[0152] Accordingly, setting the length of the aperture 60 on the
basis of Expression 1 makes it possible to avoid disadvantages as
mentioned above that may be derived from the positional deviation
of the solder-including electrode 30 caused by the thermal
expansion coefficients. Hence, it is possible to provide the
structure having the optimal yield and reliability.
Modification Example 2-1
An Example in which the Aperture has a Planar Shape of an
Ellipse
[0153] FIG. 10 illustrates, in an enlarged manner, part of a
semiconductor device according to a modification example 2-1.
Specifically, FIG. 10 illustrates a plan configuration of the two
adjacent wirings 50 (50A and 50B) in the vicinity of the peripheral
part of the chip mounting region 20A. It is to be noted that the
semiconductor chip 10 and the underfill resin 40 are omitted in the
top view of FIG. 10 for an easier understanding, but the
semiconductor chip 10 may be disposed in the region leftward of the
chip outline 10A of the semiconductor chip 10 denoted by the broken
line.
[0154] In this modification example, the aperture 60 may have a
planar shape of an ellipse elongated in the lengthwise direction DL
of the wiring 50 inside the aperture 60. This makes it possible to
increase the area of the exposed region of the wiring 50, and to
provide larger allowance for the positional deviation between the
solder-including electrode 30 and the aperture 60. Otherwise, a
semiconductor device 2A according to this modification example may
have similar configurations, workings, and effects to those of the
semiconductor device 2 according to the foregoing second
embodiment. Description is therefore given with corresponding
components denoted by same reference characters.
[0155] In one preferred example, the aperture 60 of the solder
resist layer 24 may be positioned at a distance d60 of a certain
value or more from the adjacent aperture 60, because the solder
resist is the negative photosensitive material. Accordingly, in one
desirable example, the pitch between the plurality of
solder-including electrodes 30 may be set at a large value, with
the apertures 60 shaped like rectangles as described in the
forgoing first embodiment, when the length L of the aperture 60 of
the solder resist layer 24 is set to a large value in order to use
the semiconductor chip 10 of a larger size or the packaging
substrate 20 having a large linear expansion coefficient such as a
coreless substrate.
[0156] In this modification example, the aperture 60 may have the
planar shape of the ellipse elongated in the lengthwise direction
DL of the wiring 50 inside the aperture 60. Hence, it is possible
to increase the area of the exposed region of the wiring 50 inside
the aperture 60, while keeping the distance d60 from the adjacent
aperture 60 at the certain value. As a result, it is possible to
provide the larger allowance for the positional deviation between
the solder-including electrode 30 and the aperture 60 caused by the
difference in the thermal expansion coefficients of the
semiconductor chip 10 and the packaging substrate 20, while
maintaining the pitch between the plurality of solder-including
electrodes 30. In other words, it is possible to prevent the solder
layer 32 from running on the solder resist layer 24 and causing the
short circuit between the adjacent wirings 50, or to prevent a
failure in the bonding between the solder layer 32 and the wiring
50, even in a case with the use of the semiconductor chip 10 of the
larger size or the packaging substrate 20 having the larger thermal
expansion coefficient, or a case with a higher process temperature.
Moreover, it is also possible to increase the area of the region in
which the solder layer 32 and the wiring 50 form the alloy layer,
leading to higher bonding strength and enhancement in the yield and
the reliability. Furthermore, an increase in the volume of the
aperture 60 exclusive of the volume of the wiring 50 may be
suppressed, as compared to a case with the rectangular shaped
aperture 60 as illustrated in FIG. 11. This makes it possible to
fill the aperture 60 with the solder layer 32 without increasing
the volume of the solder layer 32, while producing the effects as
described above.
[0157] As described, in this modification example, the aperture 60
may have the planar shape of the ellipse. Hence, it is possible to
increase the area of the exposed region of the wiring 50 without
reducing the distance d60 between the apertures 60, that is,
without increasing resolution of the solder resist. This allows for
the larger allowance for the positional deviation between the
solder-including electrode 30 and the aperture 60, and the enhanced
bonding strength.
Modification Example 2-2
An Example in which, Inside the Aperture, the Wiring Includes a
Widened Part
[0158] FIG. 12 illustrates, in an enlarged manner, part of a
semiconductor device according to a modification example 2-2.
Specifically, FIG. 12 illustrates a plan configuration of the two
adjacent wirings 50 (50A and 50B) in the vicinity of the peripheral
part of the chip mounting region 20A. It is to be noted that the
semiconductor chip 10, the plurality of solder-including electrodes
30, and the underfill resin 40 are omitted in the top view of FIG.
12 for an easier understanding, but the semiconductor chip 10 may
be disposed in the region leftward of the chip outline 10A of the
semiconductor chip 10 denoted by the broken line. Also, in FIG. 12,
positions at which the plurality of solder-including electrodes 30
are mounted are denoted by a broken line.
[0159] In this modification example, inside the aperture 60, each
of the plurality of wirings 50 may include a widened part 55. This
makes it possible to increase the area of the region in which the
solder-including electrode 30 and the wiring 50 form the alloy
layer, leading to even higher strength of the bonding part.
Otherwise, a semiconductor device 2B according to this modification
example may have similar configurations, workings, and effects to
those of the semiconductor device 2 according to the foregoing
second embodiment. Description is therefore given with
corresponding components denoted by same reference characters.
[0160] The plurality of wirings 50 each may be disposed inside the
aperture 60 with both of the side surfaces 54 exposed, and each may
include the widened part 55 in which the width W50 is partly
increased. This causes the increase in the area of the region in
which the solder layer 32 and the wiring 50 form the alloy layer.
Hence, it is possible to enhance the bonding strength against
shearing stress generated by the thermal stress or stress generated
by other reasons and applied to the solder bonding part. This leads
to the enhancement in the yield and the reliability.
Modification Example 2-3
An Example in which, Inside the Aperture, the Wiring has a
Break
[0161] FIG. 13 illustrates, in an enlarged manner, part of a
semiconductor device according to a modification example 2-3.
Specifically, FIG. 13 illustrates a plan configuration of the two
adjacent wirings 50 (50A and 50B) in the vicinity of the peripheral
part of the chip mounting region 20A. It is to be noted that the
semiconductor chip 10, the plurality of solder-including electrodes
30, and the underfill resin 40 are omitted in the top view of FIG.
13 for an easier understanding, but the semiconductor chip 10 may
be disposed in the region leftward of the chip outline 10A of the
semiconductor chip 10 denoted by the broken line. Moreover, in FIG.
13, the positions at which the plurality of solder-including
electrodes 30 are mounted are denoted by the broken line.
[0162] In this modification example, inside the aperture 60, each
of the plurality of wirings 50 may have a break 56. This makes it
possible to increase the area of the region in which the
solder-including electrode 30 and the wiring 50 form the alloy
layer, leading to even higher strength of the bonding part.
Otherwise, a semiconductor device 2C according to this modification
example may have similar configurations, workings, and effects to
those of the semiconductor device 2 according to the foregoing
second embodiment. Description is therefore given with
corresponding components denoted by same reference characters.
[0163] FIG. 14 illustrates a cross-sectional configuration along a
line XIV-XIV of FIG. 13. Each of the wirings 50 may be broken
inside the aperture 60, and have the break 56. A distance d56 of
the break 56 may be, for example, about 10 .mu.m. The height H50 of
the wiring 50 may be, for example, 15 .mu.m. With this
configuration, it is possible to increase area of contact of the
solder-including electrode 30 and the wiring 50, leading to higher
bonding strength. Moreover, if there should occur peeling off of
the alloy layer formed by the surface coating 52 of the wiring 50
and the solder layer 32, it is possible to prevent the peeling off
from advancing any more, thanks to discontinuity of the wiring
50.
Modification Example 2-4
An Example in which Two Apertures have Oblique Notches at their
Corners, and the Two Apertures are Adjacently Disposed with the
Oblique Notches Confronted with Each Other
[0164] FIG. 15 is an enlarged top view of part of a semiconductor
device according to a modification example 2-4. Specifically, FIG.
15 illustrates a plan configuration of the two adjacent wirings 50
(50A and 50B) in the vicinity of the peripheral part of the chip
mounting region 20A. It is to be noted that the semiconductor chip
10, the plurality of solder-including electrodes 30, and the
underfill resin 40 are omitted in the top view of FIG. 15, but the
semiconductor chip 10 may be disposed in the region leftward of the
chip outline 10A of the semiconductor chip denoted by the broken
line.
[0165] In this modification example, the two apertures 60A and 60B
may have oblique notches 62 at their angles (corners). The two
apertures 60A and 60B may be disposed with the oblique notches 62
confronted with each other. Hence, in this modification example, it
is possible to reduce the distance d30 between the solder-including
electrodes 30 even more. Otherwise, a semiconductor device 2D
according to this modification example may have similar
configurations, workings, and effects to those of the semiconductor
device 2 according to the foregoing second embodiment. Description
is therefore given with corresponding components denoted by same
reference characters.
[0166] In one preferred example, the distance d60 between the
apertures 60 may be a certain value or more because the solder
resist is generally the negative photosensitive material. In this
modification example, the adjacent apertures 60 may have the
oblique notches 62 at their corners, with the solder resist layer
24 left unremoved. In this way, it is possible to reduce the
distance d30 between the solder-including electrodes 30, while
keeping the distance d60 between the apertures 60 at the certain
value, as compared to the case with the rectangular apertures 60.
Moreover, there is little change in the allowance for the
positional deviation between the solder-including electrode 30 and
the aperture 60, from the case with the apertures 60 shaped like
rectangles. The positional deviation may be caused by the
difference in the thermal expansion coefficients of the
semiconductor chip 10 and the packaging substrate 20.
[0167] In one preferred example, the oblique notch 62 may be
arranged to avoid overlap with the wiring 50, so as not to extend
over the wiring 50. This makes it possible to prevent the area of
the exposed region of the wiring 50 inside the aperture 60 from
being affected by the oblique notches 62. Accordingly, it is
possible to provide the sufficient area of the region in which the
solder-including electrode 30 and the wiring 50 form the alloy
layer, and to maintain the bonding strength even when the distance
d30 between the solder-including electrodes 30 is reduced.
Modification Example 2-5
An Example in which Two Apertures have Oblique Notches at their
Sides, and the Two Apertures are Adjacently Disposed with the
Oblique Notches Confronted with Each Other
[0168] FIG. 16 is an enlarged top view of part of a semiconductor
device according to a modification example 2-5. Specifically, FIG.
16 illustrates a plan configuration of the two adjacent wirings 50
(50A and 50B) in the vicinity of the peripheral part of the chip
mounting region 20A. It is to be noted that the semiconductor chip
10, the plurality of solder-including electrodes 30, and the
underfill resin 40 are omitted in the top view of FIG. 16 for an
easier understanding, but the semiconductor chip 10 may be disposed
in the region leftward of the chip outline 10A of the semiconductor
chip denoted by the broken line.
[0169] In this modification example, each of the two apertures 60A
and 60B may have the oblique notch 62 along an entirety of its one
side. The two apertures 60A and 60B may be adjacently disposed with
the oblique notches 62 confronted with each other. Hence, in this
modification example, it is possible to reduce the distance d30
between the solder-including electrodes 30 even more, and to
enhance the bonding strength even more. Otherwise, a semiconductor
device 2E according to this modification example may have similar
configurations, workings, and effects to those of the semiconductor
device 2 according to the foregoing second embodiment. Description
is therefore given with corresponding components denoted by same
reference characters.
[0170] In this modification example, the two apertures 60A and 60B
each may have the oblique notch 62 at one side, and have a planar
shape of a trapezoid including one oblique side. Thus, the adjacent
apertures 60A and 60B each may include one oblique side with
respect to the lengthwise direction DL of the wiring 50 inside the
aperture 60. This makes it possible to reduce the distance d30
between the solder-including electrodes 30 while maintaining the
distance d60 between the adjacent apertures 60 at the certain
value, as compared to the case with the rectangular apertures 60.
Furthermore, it is also possible to increase the bonding area
between the solder-including electrode 30 and the wiring 50. This
makes it possible to maintain the bonding strength even when the
distance d30 between the solder-including electrodes 30 is
reduced.
[0171] In this modification example, the two apertures 60A and 60B
each may have the oblique notch 62 at one side, and be shaped as
the trapezoid. Hence, it is possible to reduce the distance d30
between the solder-including electrodes 30 without increasing the
resolution of the solder resist, and to provide even more highly
densified arrangement of the solder-including electrodes 30.
Third Embodiment
A Semiconductor Device; an Example in which a Thickness of a Solder
Resist Layer Inside an Aperture is Smaller than a Thickness of the
Solder Resist Layer in a Region Other than the Aperture Out of a
Front Surface of a Substrate Body
[0172] FIG. 17 illustrates, in an enlarged manner, part of a
semiconductor device according to a third embodiment of the
disclosure. Specifically, FIG. 17 illustrates a cross-sectional
configuration of the two adjacent wirings 50 (50A and 50B) in the
vicinity of the peripheral part of the chip mounting region
20A.
[0173] In a semiconductor device 3, a thickness t1 of the solder
resist layer 24 inside the aperture 60 may be smaller than a
thickness t2 of the solder resist layer 24 in a region other than
the aperture 60 out of the front surface of the substrate body 21.
Hence, in this embodiment, it is possible to enhance
controllability of the shape of the aperture 60, and to enhance
adhesion strength of the packaging substrate 20 and the wiring 50.
Otherwise, the semiconductor device 3 according to this embodiment
may have similar configurations, workings, and effects to those of
the semiconductor device 2 according to the foregoing second
embodiment. Description is therefore given with corresponding
components denoted by same reference characters.
[0174] In this embodiment, the solder resist layer 24 inside the
aperture 60 may allow part in the heightwise direction of the side
surfaces 54 of the wiring 50 to be exposed, without allowing the
insulating layer 21C of the substrate body 21 of the packaging
substrate 20 to be exposed. The surface coating 52 of the wiring 50
may be provided on the region exposed from the solder resist layer
24 out of the surface of the wiring 50. In one specific example,
the thickness H50 of the wiring 50 may be, for example, 15 .mu.m.
The thickness t2 of the solder resist layer 24 may be, for example,
20 .mu.m. An amount of exposure of the side surfaces 54 of the
wiring 50 may be, for example, about 10 .mu.m. The thickness t1 of
the solder resist layer 24 inside the aperture 60 may be, for
example, about 5 .mu.m. Such a structure may be easily created by
stopping development halfway, instead of carrying out the
development to the end, because the solder resist layer 24 may be
made of a negative resist in general. It is possible to reduce
development time as compared to a case in which the development is
carried out until the insulating layer 21C of the substrate body 21
of the packaging substrate 20 is exposed. This makes it possible to
miniaturize the size of the apertures 60.
[0175] Moreover, in this embodiment, the wiring 50 may have a shape
that is partly embedded in the solder resist layer 24, instead of
having all in the heightwise direction of the side surfaces 54
exposed. It is therefore possible to suppress the wiring 50 from
peeling off from the insulating layer 21C of the substrate body 21
of the packaging substrate 20.
[0176] In addition, an aspect ratio in a depthwise direction of the
aperture 60 may be lowered, and the amount of the solder filled in
the aperture 60 may be also reduced. It is therefore possible to
easily fill the aperture 60 with the solder layer 32. As a result,
it is possible to prevent generation of a minute void inside the
aperture 60, to prevent swelling of the void in the post-processes
such as the reflow process for ball attachment and the reflow
process for secondary mounting, and to prevent degradation in the
yield and the reliability.
[0177] In addition, as described in the second embodiment, the
aperture 60 may be elongated in the lengthwise direction DL of the
wiring 50 inside the aperture 60, to increase the area of the
exposed region of the wiring 50 in the lengthwise direction DL.
This makes it possible to compensate an amount of reduction in the
bonding area due to the reduction in the exposed region of the
wiring 50 in the depthwise direction.
[0178] As described, in this embodiment, the solder resist layer 24
may allow the upper surface 53 and part in the heightwise direction
of the side surfaces 54 of the wiring 50 inside the aperture 60 to
be exposed. The solder resist layer 24 may cover remaining part in
the heightwise direction of the side surfaces 54 of the wiring 50
inside the aperture 60. Moreover, the solder resist layer 24 may
cover the upper surface 53 and all in the heightwise direction of
the side surfaces 54 of each of the plurality of wirings 50 in the
region other than the aperture 60 out of the front surface of the
substrate body 21. With this configuration, it is unnecessary to
carry out the development of the solder resist layer 24 inside the
aperture 60 for all in the thicknesswise direction of the solder
resist layer 24. Hence, it is possible to enhance the resolution of
the solder resist, to form the fine aperture 60, and to increase
density of the plurality of wirings 50 even more.
[0179] Moreover, the configuration in which not all in the
heightwise direction of the side surfaces 54 of the wiring 50 is
exposed makes it possible to enhance the adhesion strength between
the wiring 50 and the insulating layer 21C of the substrate body 21
of the packaging substrate 20. It is also possible to prevent the
solder material from intruding into an interface between the wiring
50 and the insulating layer 21C of the substrate body 21 of the
packaging substrate 20 and causing lowered adhesion strength.
Furthermore, it is possible to reduce the volume of the solder
filled in the aperture 60.
Fourth Embodiment
A Semiconductor Device; an Example of an MCM (Multi Chip
Module)
[0180] FIG. 18 schematically illustrates an overall configuration
of a semiconductor device according to a fourth embodiment of the
disclosure. FIG. 19 schematically illustrates a cross-sectional
configuration of the semiconductor device, taken along a line
XIX-XIX. While the second embodiment describes a case in which the
semiconductor device 2 may be an LSI package including the
semiconductor chip 10 as a single body, a semiconductor device 4
according to this embodiment may be, for example, an application
example to an MCM (Multi Chip Module). Otherwise, the semiconductor
device 4 according to this embodiment may have similar
configurations, workings, and effects to those of the semiconductor
device 2 according to the foregoing second embodiment. Description
is therefore given with corresponding components denoted by same
reference characters.
[0181] The semiconductor device 4 may include, for example, the
semiconductor chip 10, the packaging substrate 20, the via 22, the
solder ball 23, the plurality of solder-including electrodes 30,
the underfill resin 40, and the plurality of wirings 50. These may
have similar configurations as those in the second embodiment.
[0182] Moreover, the packaging substrate 20 may include the solder
resist layer 24, and have the apertures 60, as with the second
embodiment.
[0183] As with the second embodiment, the aperture 60 may have the
planar shape elongated in the lengthwise direction DL of the wiring
50 inside the aperture 60. The length L of the aperture 60 may be
adjusted in accordance with the thermal expansion coefficient of
the packaging substrate 20. Hence, in the semiconductor device 4,
as with the second embodiment, it is possible to alleviate the
influence of the positional deviation between the aperture 60 and
the solder-including electrode 30, and to suppress the short
circuit between the adjacent wirings 50.
[0184] For example, two semiconductor packages 70 may be further
mounted on the front surface 21A of the substrate body 21 of the
packaging substrate 20, in addition to the semiconductor chip 10.
The underfill resin 40 may be provided between the packaging
substrate 20 and each of the semiconductor packages 70.
[0185] The semiconductor package 70 may have a configuration in
which, for example, a semiconductor chip 71 may be wire-bonded to a
packaging substrate 72 with a wire 73, and sealed with a mold resin
74. The semiconductor package 70 may be connected to the plurality
of wirings 50 on the packaging substrate 20 through solder balls 75
that may serve as external electrodes.
[0186] For example, when DRAM is used for the semiconductor package
70, it is desirable to increase the number of the wirings 50 that
connect the semiconductor chip 10 to the semiconductor package 70,
in order to provide a wide band. Accordingly, the foregoing second
embodiment may be applied to the semiconductor device 4 according
to this embodiment, and the length L of the aperture 60 may be
adjusted in accordance with the thermal expansion coefficient of
the packaging substrate 20. This makes it possible to reduce the
short circuit between the adjacent wirings 50, and to enjoy the
advantages of the foregoing second embodiment that involves the
flip chip connection with use of the wirings 50 arranged at the
narrow pitch.
[0187] It is to be noted that the semiconductor package 70 may not
be a packaged semiconductor component, but may be, for example, a
bare chip. In one example, a wide band memory that may be called a
wide I/O (Wide I/O) may be mounted as a bare chip, and connection
may be formed on the packaging substrate 20 with use of the fine
wirings 50. In this way, it is possible to provide an even wider
band.
Fifth Embodiment
A Semiconductor Device; an Example of Sealing with a Mold Resin
[0188] FIG. 20 schematically illustrates an overall configuration
of a semiconductor device according to a fifth embodiment of the
disclosure. A semiconductor device 5 may have a configuration in
which the semiconductor device 2 as described in the foregoing
second embodiment may be sealed with a mold resin 80. Sealing the
semiconductor device 2 with the mold resin 80 makes it possible to
protect the rear surface of the semiconductor chip 10 and the front
surface 21A of the substrate body 21 of the packaging substrate 20.
This allows for easier handling, and makes it possible to provide
the flip chip semiconductor device 5 that is resistant to impact
from outside.
[0189] On the other hand, the mold resin 80 may be accompanied by
curing shrinkage, because the mold resin 80 uses an epoxy modified
material. Moreover, the mold resin 80 has a different thermal
expansion coefficient from those of the semiconductor chip 10 and
the packaging substrate 20. This may easily cause an increase in
the stress applied to the bonding parts between the plurality of
solder-including electrodes 30 and the plurality of wirings 50.
[0190] In the semiconductor device 5 according to the embodiment,
as described in the second embodiment, in the semiconductor device
2, the aperture 60 of the solder resist layer 24 may have the
planar shape elongated in the lengthwise direction DL of the wiring
50 inside the aperture 60. The length L of the aperture 60 may be
adjusted in accordance with the thermal expansion coefficient of
the packaging substrate 20. Hence, it is possible to alleviate the
influence of the positional deviation between the aperture 60 and
the solder-including electrode 30, and to reduce the short circuit
between the adjacent wirings 50. It is also possible to increase
the area of the bonding part between the solder-including electrode
30 and the wiring 50, and to alleviate influences of the increase
in the stress derived from the mold resin 80. Accordingly, it is
possible to provide the flip chip semiconductor device 5 having
more optimal connection reliability.
Modification Example 5-1
[0191] Moreover, as illustrated in FIG. 21, the foregoing effects
may be also produced in a semiconductor device 5A in which a
semiconductor chip 90 may be stacked inside the mold resin 80. The
semiconductor chip 90 may be different from the semiconductor chip
10. The semiconductor chip 90 may include, for example, a chip body
91. The chip body 91 may be connected to the packaging substrate 20
through a wire 92.
Modification Example 5-2
[0192] Furthermore, as illustrated in FIG. 22, effects similar to
those as described above may be also obtained in a PoP (Package on
Package) semiconductor device 5B in which another semiconductor
package 100 may be further stacked on the semiconductor chip 10 of
the semiconductor device 2 as described in the second
embodiment.
[0193] The semiconductor package 100 may have a configuration in
which, for example, semiconductor chips 101A and 101B may be
wire-bonded to a packaging substrate 102 with wires 103A and 103B,
and sealed with a mold resin 104. The semiconductor package 100 may
be connected to the plurality of wirings 50 on the packaging
substrate 20, through solder balls 105 that may serve as external
electrodes.
Sixth Embodiment
A Method of Manufacturing a Semiconductor Device; an Example of
Batch Reflow
[0194] FIGS. 23 to 30, and FIGS. 31 to 34 illustrate a method of
manufacturing a semiconductor device according to a sixth
embodiment of the disclosure, in the order of procedure.
[0195] It is to be noted that the following description is given on
a case of manufacturing the semiconductor device 1 or 2 as
described in the foregoing first or second embodiment by the
manufacturing method according to this embodiment. However, the
manufacturing method according to this embodiment may be applicable
not only to the case of manufacturing the semiconductor device 1 or
2 according to the foregoing first or second embodiment, but also
to cases of manufacturing semiconductor devices according to other
embodiments and modification examples.
[0196] Description is given first on a method of manufacturing the
plurality of solder-including electrodes 30 with reference to FIGS.
23 to 30. FIG. 23 illustrates the semiconductor chip 10 in a wafer
state before formation of the plurality of solder-including
electrodes 30. The passivation film 14 may be formed on the
element-formation surface 11A of the chip body 11 made of silicon
(Si). An insulating film (undepicted) may be formed on an outermost
surface of the chip body 11. The insulating film may be made of,
for example, a silicon nitride film or polyimide. The passivation
film 14 may have an opening that allows the pad 13 to be exposed.
The pad 13 may be made of, for example, aluminum.
[0197] After cleansing of a wafer surface, a surface oxide film of
the pad 13 may be removed by argon reverse sputtering. Next, as
illustrated in FIG. 24, a TiW/Cu stacked film 15 may be
sequentially stacked by sputtering. A thickness of TiW may be, for
example, 100 nm. A thickness of copper (Cu) may be, for example,
200 nm. TiW may be provided for purpose of suppression of an
increase in resistance due to formation of an alloy layer of the
pad 13 and the metal of the columnar metal layer 31 to be formed
later.
[0198] Thereafter, as illustrated in FIG. 25, a resist film 16 may
be formed by spin coating on a front surface of the semiconductor
chip 10 in the wafer state. A thickness of the resist film 16 may
be, for example, about 70 .mu.m.
[0199] Thereafter, as illustrated in FIG. 26, a resist opening 16A
may be formed at a position at which the solder-including electrode
30 is formed, by photolithography with use of an exposure machine
such as a stepper or an aligner. When using the negative resist,
exposure may be carried out with use of a mask that allows for
exposure of a region other than the resist opening 16A. Thereafter,
development may be carried out to form the resist opening 16A.
[0200] Thereafter, resist residue that remains in a bottom of the
resist opening 16A may be cleaned up by, for example, a scum
removal process. As illustrated in FIG. 27, the columnar metal
layer 31 may be formed by electroplating. In a peripheral part of
the semiconductor chip 10 in the wafer state, an edge of the resist
film 16 may be cut in advance by about 3 mm. Power may be supplied
through the edge-cut part to carry out the electroplating. As an
electroplating film, for example, a copper (Cu) layer may be formed
with a diameter of 40 .mu.m and a height of 40 .mu.m. In order to
suppress excessive growth of the alloy layer of the solder to be
formed by plating later and the columnar metal layer 31, nickel
(Ni) electroplating may be successively carried out after forming
the copper (Cu) layer by the electroplating, to form a stacked
structure. In this case, a thickness of the copper (Cu) plating
film may be, for example, 35 .mu.m, and a thickness of the nickel
(Ni) plating film may be, for example, 5 .mu.m.
[0201] Thereafter, as illustrated in FIG. 28, the solder layer 32
may be stacked by plating on the columnar metal layer 31. A
thickness of the plating may be, for example, 26 .mu.m. A
composition of the solder may be, for example, Sn--Ag. The solder
layer 32 may be formed with other solder materials that may be used
in plating, by a similar manufacturing method. Plating of the
solder material having a low melting point, e.g., indium (In),
makes it possible to lower a heating temperature during the
assembly process, and to reduce the thermal stress during the
assembly.
[0202] Thereafter, as illustrated in FIG. 29, the resist film 16
may be removed. The TiW/Cu stacked film 15 may be removed by wet
etching, with the columnar metal layer 31 serving as a mask.
Ammonia hydrogen peroxide water may be used for TiW etching. A
mixed liquid of citric acid and aqueous hydrogen peroxide may be
used for Cu etching.
[0203] Thereafter, as illustrated in FIG. 30, a reflow process may
be carried out to remove an oxide film on a surface of the solder
layer 32 and to melt the solder layer 32. Examples may include a
method of coating the wafer surface with flux and thereafter
heating in a reflow furnace, and a method of heating in a reflow
furnace under an atmosphere of formic acid. For example, a method
may be used in which the wafer may be heated to about 250.degree.
C. under the atmosphere of formic acid to remove the surface oxide
film of the solder layer 32 and to melt the solder layer 32.
Thereafter, water cleansing treatment may be carried out to remove
residue or a foreign matter that are attached to the surface.
Thereafter, a protection tape may be attached to the
element-formation surface 11A of the semiconductor chip 10 in the
wafer state. Thereafter, back grinding may be carried out to a
predetermined thickness, to adjust a thickness of the chip body 11
to an appropriate value. Thereafter, the chip body 11 may be fixed
to a dicing frame with a dicing tape. After removal of the
protection tape, dicing may be carried out. Thus, the semiconductor
chip 10 including the plurality of solder-including electrodes 30
may be completed.
[0204] At this occasion, possible advantages of the columnar metal
layer 31 made of the metal having the higher melting point than
that of the solder that constitutes the solder layer 32 may be as
follows. When most part of an electrode is made of solder as in the
existing C4 technique, the solder electrode may tend to keep itself
in a spherical shape, owing to action of a force that keeps surface
tension to a minimum when the solder melts. In order to provide a
gap for injection of the underfill resin 40 between the
semiconductor chip 10 and the packaging substrate 20, it is
preferable that a solder electrode having a large diameter be
prepared when most part of the electrode is made of the solder. It
is therefore difficult to reduce the pitch between the electrodes.
In this embodiment, the plurality of solder-including electrodes 30
may have the stacked configuration of the columnar metal layer 31
and the solder layer 32. The columnar metal layer 31 may not melt
at the melting point of the solder. This makes it possible to
reduce the inter-electrode pitch between the plurality of
solder-including electrodes 30, while providing the sufficient gap
G between the semiconductor chip 10 and the packaging substrate
20.
[0205] It is to be noted that the foregoing method of manufacturing
the plurality of solder-including electrodes 30 may be applicable
to sixth and seventh embodiments to be described later.
[0206] In the following, description is given on a method of
connecting, by batch reflow, the packaging substrate 20 and the
semiconductor chip 10 with reference to FIGS. 31 to 34.
[0207] First, as illustrated in FIG. 31, the solder-including
electrode 30A may be aligned with the aperture 60A on the wiring
50A as the connection target, with flux (undepicted) applied in
advance by dipping to a tip of the solder layer 32 of the
solder-including electrode 30A.
[0208] Next, as illustrated in FIG. 32, an appropriate load may be
applied at an appropriate temperature, to pressure-bond the solder
layer 32 to the wiring 50A. At this phase, the solder layer 32 and
the surface coating 52 of the wiring 50A may not be completely
alloyed, but may be fixed with adhesiveness of the flux
material.
[0209] At this occasion, applying the load excessively may cause
the gap G between the semiconductor chip 10 and the packaging
substrate 20 to become small. Because of rigidity of the wiring 50
and the columnar metal layer, the solder layer 32 present
therebetween may be expelled and protrude from the aperture 60 to
outside, resulting in the possibility of the short circuit.
[0210] In this embodiment, as described above in the first
embodiment, the plurality of solder-including electrodes 30 are
each provided with the function of serving as the gap control
electrode, and the overlap region OL where the columnar metal layer
31 and the solder resist layer 24 overlap each other is provided
along part or all of the aperture end 61 of the aperture 60.
Accordingly, the gap G between the semiconductor chip 10 and the
packaging substrate 20 may be self-alignedly kept at the height H31
of the columnar metal layer 31 or more. This avoids the
disadvantage of the short circuit as described above.
[0211] Thereafter, heating in the reflow furnace may be carried
out, to cause alloying of the solder layer 32 and the surface
coating 52 of the wiring 50A, as illustrated in FIG. 33. At this
occasion, the flux material may have a function of removing the
surface oxide film of the solder layer 32.
[0212] Moreover, at this occasion, there may occur the positional
deviation between the solder-including electrode 30A and the
aperture 60A due to the difference in the thermal expansion
coefficients of the semiconductor chip 10 and the packaging
substrate 20. In general, the packaging substrate 20 may have the
larger thermal expansion coefficient. Accordingly, with the plan
configuration of the packaging substrate 20 as illustrated in FIG.
1, the positional deviation may occur depthward or frontward of the
sheet of FIG. 33, i.e., in the lengthwise direction DL of the
wiring 50 inside the aperture 60.
[0213] Here, as described in the second embodiment, the aperture 60
of the solder resist layer 24 may have the planar shape elongated
in the lengthwise direction DL of the wiring 50 inside the aperture
60. The length L of the aperture 60 may be adjusted in accordance
with the thermal expansion coefficient of the packaging substrate
20. Accordingly, as illustrated in FIG. 9, the solder layer 32 may
be suppressed from running on the solder resist layer 24 and
causing the short circuit with the adjacent wiring 50B.
[0214] It is to be noted that the reflow process may be carried out
a plurality of times, in order to promote the alloying.
[0215] Thereafter, cleansing may be carried out to remove the flux
material. As illustrated in FIG. 34, the underfill resin 40 may be
injected into the gap between the semiconductor chip 10 and the
packaging substrate 20. Thereafter, curing may be carried out to
modify and cure the underfill resin 40. In injecting the underfill
resin 40, the packaging substrate 20 may be heated to, for example,
about 80.degree. C. After injection, post-curing may be carried
out, for example, at 150.degree. C. for about 1.5 hours in
total.
[0216] Thereafter, flux may be transferred to the positions at
which the solder balls 23 are mounted, on the rear surface 21B of
the substrate body 21 of the packaging substrate 20. The solder
balls 23 may be mounted. The reflow process for the ball attachment
may be carried out. As a result, the solder layer 32 may melt
again. At this occasion, the surface coating 52 of the wiring 50
may contribute to suppression of the excessive alloying of the
solder layer 32 and the wiring 50 to cause degradation in the
bonding strength. Furthermore, regarding the thermal stress
generated in a cooling step after the reflow, the length L of the
aperture 60 on the wiring 50 may be increased to expand the area of
the bonding part. This makes it possible to enhance the mechanical
strength.
[0217] In this embodiment, the semiconductor chip 10 and the
packaging substrate 20 may be temporarily bonded with use of the
flux. Thereafter, the reflow heating may be carried out. This
causes the semiconductor chip 10 and the packaging substrate 20 to
be heated to the same high temperature. Accordingly, the amount of
the positional deviation due to the difference in the thermal
expansion coefficients of the semiconductor chip 10 and the
packaging substrate 20 may tend to be large. However, as described
in the second embodiment, the aperture 60 of the solder resist
layer 24 may have the planar shape elongated in the lengthwise
direction DL of the wiring 50 inside the aperture 60. The length L
of the aperture 60 may be adjusted in accordance with the thermal
expansion coefficient of the packaging substrate 20. Hence, it is
possible to alleviate the influence of the positional deviation
between the aperture 60 and the solder-including electrode 30, and
to suppress the short circuit between the adjacent wirings 50.
[0218] Moreover, in this embodiment, the semiconductor chip 10 may
be heated, in an unfixed state, to the temperature equal to or
higher than the melting point of the solder. Accordingly, the
positional deviation or inclination of the semiconductor chip 10
may be corrected by a self-alignment effect of the solder. Hence,
it is possible to provide high alignment precision even in a case
in which the plurality of solder-including electrodes 30 and the
plurality of wirings 50 are arranged at a narrow pitch. This allows
for production with even smaller variations, and with stabilization
of the shape of the bonding part between the solder-including
electrode 30 and the wiring 50. This leads to the enhancement in
the yield and the reliability.
[0219] Furthermore, the use of the batch reflow allows for
successive treatment in the reflow furnace, optimal productivity,
and lower costs.
[0220] In addition, as described in the first embodiment, the
plurality of solder-including electrodes 30 are each provided with
the function of serving as the gap control electrode, and the
overlap region OL where the columnar metal layer 31 and the solder
resist layer 24 overlap each other is provided along part or all of
the aperture end 61 of the aperture 60. Therefore, at a phase in
which the columnar metal layer 31 and the solder resist layer 24
come in contact with each other, it is difficult to press down the
semiconductor chip 10 any further. This makes it possible to
self-alignedly keep the gap G between the semiconductor chip 10 and
the packaging substrate 20 at the height H31 of the columnar metal
layer 31 or more. Accordingly, it is possible to restrain the
solder layer 32 from being excessively expelled to cause the short
circuit, in temporarily bonding the semiconductor chip 10 to the
packaging substrate 20.
Seventh Embodiment
A Method of Manufacturing a Semiconductor Device; an Example of
Local Reflow
[0221] Description is given next on a method of connection between
the packaging substrate 20 and the semiconductor chip 10, with use
of a local reflow method called thermal compression (Thermal
Compression), with reference to FIGS. 31, 33, and 34 as well.
[0222] First, as illustrated in FIG. 31, the solder layer 32 of the
solder-including electrode 30A may be aligned with the aperture 60A
on the wiring 50A as the connection target.
[0223] Next, as illustrated in FIG. 33, an appropriate load may be
applied at an appropriate temperature, to perform
thermocompression. In one example, the semiconductor chip 10 and
the packaging substrate 20 may be heated in advance to about
100.degree. C. that is equal to or lower than the melting point of
the solder. The semiconductor chip 10 may be pressed onto the
packaging substrate 20 until a load cell on apparatus side detects
a load. At this occasion, because the wiring 50 is shaped as a
protrusion and made of a hard material, it is possible to impart a
function of destroying the surface oxide film of the solder layer
32 to the wiring 50.
[0224] Incidentally, when the semiconductor chip 10 has been
already heated to the temperature equal to or higher than the
melting point of the solder at a stage before the
thermocompression, oxidation of the solder may proceed, which may
cause the bonding failure. Desirable countermeasures may include
processing under an inert atmosphere or a reducing atmosphere, but
it is conceivable that preparing such an environment may be
difficult in a production plant. In such a case, as described
above, the temperature may not be raised during the alignment of
the semiconductor chip 10 with the packaging substrate 20. Instead,
heating may be carried out after the load is detected by allowing
the semiconductor chip 10 and the packaging substrate 20 to be in
contact with each other.
[0225] After the detection of the load, a temperature of a tool
that fixes the semiconductor chip 10 may be started to rise. The
temperature of the tool may be adjusted to allow an effective
temperature of the solder part to exceed the melting point of the
solder. At this occasion, the heating may be accompanied by thermal
expansion in a tool part of the apparatus. Accordingly, in order to
cancel the thermal expansion on tool side, the apparatus may be
instructed to operate to pull up the semiconductor chip 10 so as
not to destroy the bonding part. After performing adjustment to
provide the appropriate gap G between the semiconductor chip 10 and
the packaging substrate 20, the tool may be cooled down to solidify
the solder layer 32 and to complete the bonding. At this occasion
as well, the cooling may be accompanied by shrinkage on the tool
side. Accordingly, in order to cancel the shrinkage, the apparatus
may be instructed to operate to press down the semiconductor chip
10. In a step after the load detection, it is desirable to adjust
the gap G between the semiconductor chip 10 and the packaging
substrate 20 to a value as constant as possible.
[0226] An amount of the thermal expansion of the tool may vary
depending on the apparatus, and be expected to change with time.
Therefore, a considerably complicated production recipe has been
prepared for each production facility, and operation has been
confirmed regularly.
[0227] In this embodiment, as described above in the first
embodiment, the plurality of solder-including electrodes 30 are
each provided with the function of serving as the gap control
electrode, and the overlap region OL where the columnar metal layer
31 and the solder resist layer 24 overlap each other is provided
along part or all of the aperture end 61 of the aperture 60.
Accordingly, the load may be detected at a point of time when the
columnar metal layer 31 comes into contact with the solder resist
layer 24, and it may be difficult to press down the semiconductor
chip 10 any further. This may allow the gap G between the
semiconductor chip 10 and the packaging substrate 20 to be
self-alignedly kept at the height H31 of the columnar metal layer
31 or more. It is therefore unnecessary to instruct each apparatus
to perform the different pulling-up operation, and it is possible
to obtain an optimal bonding shape, while maintaining the constant
gap G even during the rise in the temperature. It is also possible
to adjust the gap G by instructing the apparatus to pull up the
tool, at a phase in which the thermal expansion of the tool calms
down. Furthermore, even when the thermal expansion of the tool
during the rise in the temperature is greater than expected,
reduction in the gap G may be avoided. This makes it possible to
prevent the occurrence of the short circuit.
[0228] In addition, providing the overlap region OL in a peripheral
part of the columnar metal layer 31 may allow the solder layer 32
to be maintained in a shape close to a hemisphere by the reflow.
Accordingly, the amount of the expelled solder layer 32 may be
small even if the columnar metal layer 31 and the solder resist
layer 24 are allowed to be in contact with each other. This leads
to low probability of the occurrence of the short circuit with the
adjacent wiring 50.
[0229] Moreover, in order to perform optimal bonding, there may be
an additional improvement to remove the surface oxide film of the
solder layer 32, with use of ultrasonic or mechanical vibration, or
a reducing gas atmosphere such as formic acid when the solder layer
32 is heated to the temperature equal to or higher than the melting
point of the solder layer 32.
[0230] Thereafter, as illustrated in FIG. 34, the underfill resin
40 may be injected into between the semiconductor chip 10 and the
packaging substrate 20. Thereafter, the curing may be carried out
to modify and cure the underfill resin 40. The post-processes may
be the same as those in the sixth embodiment.
[0231] One advantage of using the local reflow method as described
is that it is unnecessary to allow the temperatures of the
semiconductor chip 10 and the packaging substrate 20 to be the
same, unlike the batch reflow method as described in the sixth
embodiment. In this embodiment, it is possible to allow the
temperature of the packaging substrate 20 having the larger thermal
expansion coefficient to be lower than the temperature of the
semiconductor chip 10. This makes it possible to reduce the thermal
stress generated in the cooling process in the solidification of
the solder. Accordingly, by combining the local reflow method with
the aperture 60 as described in the second embodiment, it is
possible to provide the bonding structure having even higher
strength against the thermal stress in the flip chip mounting.
[0232] Effects of this embodiment may be as follows. In a case with
shrinkage of the plurality of solder-including electrodes 30 and
the plurality of wiring 50 to increase the connection density, the
heat treatment by the batch reflow method may cause generation of
such large thermal stress that even breaking of the bonding part
may be assumed. Thus, in this embodiment, in one preferred example,
after the alignment, the tool that holds the semiconductor chip 10
may be heated to perform thermocompression. The bonding may be
carried out without directly heating the packaging substrate 20
having the larger thermal expansion coefficient to the temperature
equal to or higher than the melting point of the solder.
Accordingly, an amount of the expansion of the packaging substrate
20 may be relatively small as compared to that in the batch reflow
method. It is therefore possible to suppress the thermal stress
generated in the assembly process. In this case, in the reflow
process for the ball attachment or the reflow process for the
secondary mounting, the semiconductor chip 10 and the packaging
substrate 20 may be heated to the same temperature. However, the
heating is performed after the injection of the underfill resin 40.
Part of the thermal stress generated may be therefore shared by the
underfill resin 40, making it possible to reduce the stress applied
to the bonding part.
Eighth Embodiment
[0233] It is to be noted that description has been given in the
foregoing sixth embodiment on the method that involves the
temporarily bonding with use of the flux, and thereafter, the
heating in the reflow furnace. However, other techniques may be
utilized that involve temporarily bonding by the thermocompression
method as described in the seventh embodiment, and thereafter, the
heating in the reflow furnace, so as to promote growth of the alloy
layer even more, and thereby to ensure the bonding.
Ninth Embodiment
[0234] Moreover, in the foregoing seventh embodiment, description
has been given on a process that involves raising or lowering the
temperature of the tool that holds the semiconductor chip 10 during
the bonding process. However, a technique may be utilized that
involves thermocompression with the temperature on the tool side
fixed at the temperature equal to or higher than the melting point
of the solder. In this case, it is difficult to detect the load by
the contact of the solder layer 32 and the wiring 50. Therefore,
the load when the columnar metal layer 31 comes into contact with
the solder resist layer 24 may be detected. Alternatively, the load
when the columnar metal layer 31 comes into contact with the wiring
50 may be detected, and thereafter, the tool that holds the
semiconductor chip 10 may be pulled up so as to form the desired
gap G On the other hand, this technique may allow a surface oxide
film to grow, because the solder layer 32 is kept melting.
Accordingly, taking countermeasures such as bonding under a
nitrogen atmosphere makes it possible to obtain a more optimal
bonding state.
[0235] In particular, as described above in the first embodiment,
in one preferred example, the plurality of solder-including
electrodes 30 each may be provided with the function of serving as
the gap control electrode, and the overlap region OL where the
columnar metal layer 31 and the solder resist layer 24 overlap each
other is provided along part or all of the aperture end 61 of the
aperture 60. Accordingly, the load may be detected at the point of
time when the columnar metal layer 31 and the solder resist layer
24 come into contact with each other, and it may be difficult to
press down the semiconductor chip 10 any further. This may allow
the gap G between the semiconductor chip 10 and the packaging
substrate 20 to be self-alignedly kept at the height H31 of the
columnar metal layer 31 or more. Accordingly, the occurrence of the
short circuit due to the expelled solder layer 32 may be avoided,
and a margin for, for example, variations in the width (diameter) W
of the aperture 60 may be increased.
[0236] By using such technique, it is possible to eliminate the
complicated process of raising or lowering the temperature on the
tool side, or the fine gap adjustment due to the thermal expansion
of the tool, while enjoying the advantages of the local reflow such
as the reduction in the thermal stress as described in the seventh
embodiment. Hence, it is possible to reduce apparatus costs or
production costs even more.
Tenth Embodiment
A Method of Manufacturing a Semiconductor Device; an Example in
which an Underfill Resin is Supplied in Advance on a Packaging
Substrate
[0237] FIGS. 35 to 37 illustrate a method of manufacturing a
semiconductor device according to a tenth embodiment of the
disclosure, in the order of procedure. The manufacturing method
according to this embodiment may be different from the method of
manufacturing the semiconductor device according to the foregoing
sixth embodiment, in that the underfill resin 40 may be supplied in
advance on the packaging substrate 20.
[0238] It is to be noted that the following description is given on
a case of manufacturing the semiconductor device 1 or 2 as
described in the foregoing first or second embodiment by the
manufacturing method according to this embodiment. However, the
manufacturing method according to this embodiment may be applicable
not only to the case of manufacturing the semiconductor device 1 or
2 according to the foregoing first or second embodiment, but also
to cases of manufacturing semiconductor devices according to other
embodiments and modification examples.
[0239] First, as illustrated in FIG. 35, the underfill resin 40 may
be applied with a dispenser on the front surface 21A of the
substrate body 21 of the packaging substrate 20. The underfill
resin 40 may be made of a precoating underfill material (NCP) in a
liquid state. For the NCP, for example, NCP 5208 (Henkel) may be
used.
[0240] Next, as illustrated in FIG. 36, the solder-including
electrode 30A may be aligned with the aperture 60A on the wiring
50A as the connection target.
[0241] Thereafter, as illustrated in FIG. 37, the bonding of the
solder layer 32 and the wiring 50 may be carried out while
maintaining an appropriate temperature and a tool position in a
similar manner to the seventh embodiment. Heating at this occasion
may cause the underfill resin 40 to be cured.
[0242] In one example, the packaging substrate 20 may be heated at
a constant temperature of 70.degree. C. The semiconductor chip 10
may be pressed onto the packaging substrate 20 until a load of 50 N
is detected on the tool side. The temperature may be raised to
240.degree. C., and thereafter maintained for 2.8 seconds to
perform temporary curing. Thereafter, post-curing may be carried
out at 150.degree. C. for about 1.5 hours. Thus, the curing may be
completed.
[0243] In such a technique, it is generally well known that the NCP
material may remain between the solder layer 32 and the wiring 50
and cause the bonding failure. In an attempt to avoid this,
applying the load excessively may cause the gap G between the
semiconductor chip 10 and the packaging substrate 20 to become
small. Because of the high rigidity of the wiring 50 and the
columnar metal layer 31, the solder layer 32 present therebetween
may be expelled and protrude from the aperture 60 to outside,
resulting in the possibility of the short circuit.
[0244] In this embodiment, as described above in the first
embodiment, the plurality of solder-including electrodes 30 are
each provided with the function of serving as the gap control
electrode, and the overlap region OL where the columnar metal layer
31 and the solder resist layer 24 overlap each other is provided
along part or all of the aperture end 61 of the aperture 60.
Accordingly, the gap G between the semiconductor chip 10 and the
packaging substrate 20 may be self-alignedly kept at the height H31
of the columnar metal layer 31 or more. Hence, it is possible to
avoid a decrease in a size of the gap G and to prevent the
occurrence of the short circuit, even when the thermal expansion of
the tool during the rise in the temperature is greater than
expected.
[0245] Possible advantages of the manufacturing method according to
this embodiment may be as follows. In a structure with the
plurality of solder-including electrodes 30 (the columnar metal
layers 31) arranged at the narrow pitch, it is difficult to provide
the wide gap G between the semiconductor chip 10 and the packaging
substrate 20, as compared to the flip chip connection of the
existing C4 type. One reason may be because an aspect ratio of the
resist opening 16A becomes large when the columnar metal layer 31
is formed by plating. This causes difficulty in filling the resist
opening 16A by the plating. Accordingly, the use of the precoating
underfill resin 40 as in this embodiment makes it possible to fill
the gap G between the semiconductor chip 10 and the packaging
substrate 20 with the underfill resin 40, even when the height of
the columnar metal layer 31 is small. Moreover, because the curing
of the underfill resin 40 may be started at the cooling stage of
the bonding process, the thermal stress may be shared and received
by not only the bonding part between the solder layer 32 and the
wiring 50 but also the underfill resin 40. This makes it possible
to reduce the thermal stress received by the bonding part between
the solder-including electrode 30 and the wiring 50, and to enhance
the yield and the reliability of the semiconductor devices 1 and 2
even more.
[0246] As described, in this embodiment, the underfill resin 40 may
be supplied on the packaging substrate 20, and thereafter, the
bonding may be carried out. Hence, it is possible to reduce the
stress applied to the bonding part, as compared to the
thermocompression process as described in the sixth or seventh
embodiment.
[0247] In one specific example, the underfill resin 40 in the
liquid state may be applied to the packaging substrate 20.
Thereafter, the semiconductor chip 10 may be heated and
pressure-bonded. After the underfill resin 40 is almost cured, the
semiconductor chip 10 may be released from the tool. With this
manufacturing method, the underfill resin 40 may start curing in
the cooling process in which the thermal stress is generated.
Accordingly, the thermal stress generated may be shared and
received by the bonding part between the solder-including electrode
30 and the wiring 50 and by the underfill resin 40. This makes it
possible to reduce the stress applied to the bonding part. Hence,
it is possible to achieve further miniaturization of the plurality
of solder-including electrodes 30 and the plurality of wirings 50,
and to provide the even more highly densified flip chip
semiconductor devices 1 and 2 with the high yield and the high
reliability.
Other Effects
[0248] Description has been made on the example embodiments and
their effects as mentioned above. The foregoing effects are not
limited to a flip chip semiconductor device in which the
semiconductor chip 10 as a single body is mounted as in the first
to third embodiments. For example, the same effects may be produced
by the MCM (Multi Chip Module) structure in which a plurality of
memory packages and the semiconductor chip 10 are mounted on one
sheet of the packaging substrate 20 as in the fourth
embodiment.
[0249] Furthermore, in the structure in which the semiconductor
chip 10 is flip chip connected to the packaging substrate 20 and
sealed by the mold resin 80 as in the fifth embodiment, the stress
generated in the bonding part between the solder-including
electrode 30 and the wiring 50 tends to be larger due to the curing
shrinkage of the mold resin 80. The same applies to the structure
as described in the modification example 5-1 in which the
semiconductor chip 90 as a bare chip may be mounted on the rear
surface of the semiconductor chip 10, connected to the packaging
substrate 20 by wire bonding, and sealed by the mold resin 80. In
such structures, it is possible to obtain even higher effects by
adopting the bonding structures having optimal strength, as in the
forgoing example embodiments.
[0250] Also, there is no difference in effects produced in the PoP
(Package on Package) structure in which the additional
semiconductor package 100 may be further mounted on the
semiconductor chip 10 of the semiconductor device 2, as in the
modification example 5-2.
[0251] Although description has been made by giving the example
embodiments as mentioned above, the contents of the disclosure are
not limited to the above-mentioned example embodiments and may be
modified in a variety of ways.
[0252] For example, shapes, materials, and thicknesses, or
deposition methods or other methods of the layers as described in
the forgoing example embodiments are not limited to as exemplified
above, but other shapes, materials, and thicknesses, or other
deposition methods may be adopted.
[0253] It is to be noted that effects described herein are merely
exemplified and not limitative, and effects of the disclosure may
be other effects or may further include other effects.
[0254] The contents of the technology may have the following
configurations.
(1)
[0255] A semiconductor device, including:
[0256] a semiconductor chip; and
[0257] a packaging substrate on which the semiconductor chip is
mounted,
[0258] wherein the semiconductor chip includes a chip body and a
plurality of solder-including electrodes provided on an
element-formation surface of the chip body,
[0259] the packaging substrate includes a substrate body, a
plurality of wirings, and a solder resist layer, the plurality of
wirings and the solder resist layer being provided on a front
surface of the substrate body,
[0260] the solder resist layer is provided as a continuous layer on
the front surface of the substrate body and the plurality of
wirings, and has an aperture on each of the plurality of
wirings,
[0261] the plurality of solder-including electrodes include at
least one gap control electrode, and
[0262] the at least one gap control electrode includes a columnar
metal layer and a solder layer in order named from side on which
the chip body is disposed, and includes an overlap region where the
columnar metal layer and the solder resist layer overlap each
other, along part or all of an aperture end of the aperture.
(2)
[0263] The semiconductor device according to (1),
[0264] wherein the at least one gap control electrode includes a
plurality of gap control electrodes, and
[0265] at least one of the plurality of gap control electrodes is
disposed at each side of the semiconductor chip.
(3)
[0266] The semiconductor device according to (1) or (2),
[0267] wherein, in the at least one gap control electrode, a
diameter of the columnar metal layer is larger than a width of the
aperture, along part or all of the aperture end of the
aperture.
(4)
[0268] The semiconductor device according to (1) or (2),
[0269] wherein, in the at least one gap control electrode, a center
of the columnar metal layer is out of alignment with a center of
the aperture.
(5)
[0270] The semiconductor device according to any one of (1) to
(4),
[0271] wherein the aperture has a planar shape elongated in a
lengthwise direction of the wiring inside the aperture, with a
length of the aperture adjusted in accordance with a thermal
expansion coefficient of the packaging substrate.
(6)
[0272] The semiconductor device according to any one of (1) to
(5),
[0273] wherein the columnar metal layer is made of a metal having a
higher melting point than a melting point of solder that
constitutes the solder layer.
(7)
[0274] The semiconductor device according to (6),
[0275] wherein a height of the columnar metal layer is larger than
a height of the solder layer.
(8)
[0276] The semiconductor device according to (6) or (7),
[0277] wherein a volume of the solder layer is larger than a volume
of the aperture.
(9)
[0278] The semiconductor device according to any one of (5) to
(8),
[0279] wherein the length of the aperture satisfies Expression
1.
L>(a-3.5)*D*(T-25)*10-6+d Expression 1
[0280] (in Expression 1, L denotes the length (mm) of the aperture,
a denotes an equivalent thermal expansion coefficient (ppm/.degree.
C.) of the packaging substrate, D denotes a distance (mm) from a
center of the packaging substrate to a center of the aperture, T
denotes a melting point (.degree. C.) of the solder, and d denotes
a diameter of each of the plurality of solder-including
electrodes.)
(10)
[0281] The semiconductor device according to any one of (1) to
(9),
[0282] wherein each of the plurality of wirings includes:
[0283] a metal wiring layer made of copper (Cu) as a principal
component; and
[0284] a surface coating that covers a region exposed in the
aperture, out of a surface of the metal wiring layer.
(11)
[0285] The semiconductor device according to (10),
[0286] wherein the surface coating includes an Ni--Au plating layer
or a Ni--Pd--Au plating layer.
(12)
[0287] The semiconductor device according to any one of (1) to
(11),
[0288] wherein the columnar metal layer is made of copper (Cu), or
includes a stacked film of copper (Cu) and nickel (Ni), and
[0289] the solder layer is made of tin (Sn) or Sn--Ag.
(13)
[0290] The semiconductor device according to any one of (1) to
(11),
[0291] wherein the columnar metal layer is made of copper (Cu), or
includes a stacked film of copper (Cu) and nickel (Ni), and
[0292] the solder layer is made of indium (In) or In--Ag.
(14)
[0293] A method of manufacturing a semiconductor device, the method
including:
[0294] aligning a semiconductor chip with a packaging substrate,
the semiconductor chip including a chip body and a plurality of
solder-including electrodes provided on an element-formation
surface of the chip body, and the packaging substrate including a
substrate body, a plurality of wirings, and a solder resist layer,
the plurality of wirings and the solder resist layer being provided
on a front surface of the substrate body;
[0295] temporarily bonding the semiconductor chip to the packaging
substrate;
[0296] connecting the plurality of solder-including electrodes to
the plurality of wirings, by reflow heating; and
[0297] injecting an underfill resin between the semiconductor chip
and the packaging substrate, and curing the underfill resin,
[0298] wherein the solder resist layer is provided as a continuous
layer on the front surface of the substrate body and the plurality
of wirings, and has an aperture on each of the plurality of
wirings,
[0299] the plurality of solder-including electrodes include at
least one gap control electrode,
[0300] the at least one gap control electrode includes a columnar
metal layer and a solder layer in order named from side on which
the chip body is disposed, and
[0301] the temporarily bonding of the semiconductor chip to the
packaging substrate includes heating the semiconductor chip and
pressure-bonding the semiconductor chip to the packaging substrate,
and detecting a load by allowing the columnar metal layer of the at
least one gap control electrode and the solder resist layer to be
in contact with each other.
(15)
[0302] A method of manufacturing a semiconductor device, the method
including:
[0303] aligning a semiconductor chip with a packaging substrate
after heating the semiconductor chip at a temperature equal to or
higher than a melting point of solder, the semiconductor chip
including a chip body and a plurality of solder-including
electrodes provided on an element-formation surface of the chip
body, and the packaging substrate including a substrate body, a
plurality of wirings, and a solder resist layer, the plurality of
wirings and the solder resist layer being provided on a front
surface of the substrate body;
[0304] connecting the plurality of solder-including electrodes to
the plurality of wirings; and
[0305] injecting an underfill resin between the semiconductor chip
and the packaging substrate, and curing the underfill resin,
[0306] wherein the solder resist layer is provided as a continuous
layer on the front surface of the substrate body and the plurality
of wirings, and has an aperture on each of the plurality of
wirings,
[0307] the plurality of solder-including electrodes include at
least one gap control electrode,
[0308] the at least one gap control electrode includes a columnar
metal layer and a solder layer in order named from side on which
the chip body is disposed, and
[0309] the connecting of the plurality of solder-including
electrodes to the plurality of wirings includes pressure-bonding
the semiconductor chip to the packaging substrate, detecting a load
by allowing the columnar metal layer of the at least one gap
control electrode and the solder resist layer to be in contact with
each other, and adjusting a gap between the semiconductor chip and
the packaging substrate.
(16)
[0310] A method of manufacturing a semiconductor device, the method
including:
[0311] aligning a semiconductor chip with a packaging substrate,
the semiconductor chip including a chip body and a plurality of
solder-including electrodes provided on an element-formation
surface of the chip body, and the packaging substrate including a
substrate body, a plurality of wirings, and a solder resist layer,
the plurality of wirings and the solder resist layer being provided
on a front surface of the substrate body;
[0312] connecting the plurality of solder-including electrodes to
the plurality of wirings; and
[0313] injecting an underfill resin between the semiconductor chip
and the packaging substrate, and curing the underfill resin,
[0314] wherein the solder resist layer is provided as a continuous
layer on the front surface of the substrate body and the plurality
of wirings, and has an aperture on each of the plurality of
wirings,
[0315] the plurality of solder-including electrodes include at
least one gap control electrode,
[0316] the at least one gap control electrode includes a columnar
metal layer and a solder layer in order named from side on which
the chip body is disposed, and
[0317] the connecting of the plurality of solder-including
electrodes to the plurality of wirings includes pressure-bonding
the semiconductor chip to the packaging substrate, detecting a load
by allowing the columnar metal layer of the at least one gap
control electrode and the solder resist layer to be in contact with
each other, and heating the semiconductor chip at a temperature
equal to or higher than a melting point of the solder and
pressure-bonding the semiconductor chip to the packaging substrate,
to connect the plurality of solder-including electrodes to the
plurality of wirings.
(17)
[0318] A method of manufacturing a semiconductor device, the method
including:
[0319] supplying an underfill resin on a packaging substrate, the
packaging substrate including a substrate body, a plurality of
wirings, and a solder layer, the plurality of wirings and the
solder resist layer being provided on a front surface of the
substrate body;
[0320] aligning a semiconductor chip with the packaging substrate,
the semiconductor chip including a chip body and a plurality of
solder-including electrodes provided on an element-formation
surface of the chip body;
[0321] connecting the plurality of solder-including electrodes to
the plurality of wirings, and temporarily curing the underfill
resin; and
[0322] permanently curing the underfill resin,
[0323] wherein the solder resist layer is provided as a continuous
layer on the front surface of the substrate body and the plurality
of wirings, and has an aperture on each of the plurality of
wirings,
[0324] the plurality of solder-including electrodes include at
least one gap control electrode,
[0325] the at least one gap control electrode includes a columnar
metal layer and a solder layer in order named from side on which
the chip body is disposed, and
[0326] the connecting of the plurality of solder-including
electrodes to the plurality of wirings includes pressure-bonding
the semiconductor chip to the packaging substrate, detecting a load
by allowing the columnar metal layer of the at least one gap
control electrode and the solder resist layer to be in contact with
each other, and heating the semiconductor chip at a temperature
equal to or higher than a melting point of the solder and
pressure-bonding the semiconductor chip to the packaging substrate,
to connect the plurality of solder-including electrodes to the
plurality of wirings.
[0327] This application claims the benefit of Japanese Priority
Patent Application JP 2014-132333 filed on Jun. 27, 2014 the entire
contents of which are incorporated herein by reference.
[0328] It should be understood by those skilled in the art that
various modifications, combinations, sub-combinations and
alterations may occur depending on design requirements and other
factors insofar as they are within the scope of the appended claims
or the equivalents thereof.
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